U.S. patent application number 15/803688 was filed with the patent office on 2018-05-10 for gas flow in three-dimensional printing.
The applicant listed for this patent is Velo3D, Inc.. Invention is credited to Kenji BOWERS, Thomas Blasius BREZOCZKY, Alexander Brudny, Benyamin Buller, Zachary Ryan MURPHREE.
Application Number | 20180126650 15/803688 |
Document ID | / |
Family ID | 62065388 |
Filed Date | 2018-05-10 |
United States Patent
Application |
20180126650 |
Kind Code |
A1 |
MURPHREE; Zachary Ryan ; et
al. |
May 10, 2018 |
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.
Inventors: |
MURPHREE; Zachary Ryan; (San
Jose, CA) ; BREZOCZKY; Thomas Blasius; (Los Gatos,
CA) ; Buller; Benyamin; (Cupertino, CA) ;
BOWERS; Kenji; (San Mateo, CA) ; Brudny;
Alexander; (San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Velo3D, Inc. |
Campbell |
CA |
US |
|
|
Family ID: |
62065388 |
Appl. No.: |
15/803688 |
Filed: |
November 3, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62418601 |
Nov 7, 2016 |
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62477631 |
Mar 28, 2017 |
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62489239 |
Apr 24, 2017 |
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62549868 |
Aug 24, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 2003/1059 20130101;
B29C 64/35 20170801; B29C 64/245 20170801; B22F 2003/1056 20130101;
B22F 2999/00 20130101; B29C 64/268 20170801; B08B 15/02 20130101;
B33Y 10/00 20141201; B33Y 30/00 20141201; B33Y 50/02 20141201; Y02P
10/25 20151101; B08B 5/04 20130101; B29C 64/25 20170801; B33Y 40/00
20141201; B29C 64/371 20170801; B22F 2201/00 20130101; B29C 64/153
20170801; B22F 3/1055 20130101; B22F 2003/1057 20130101; Y02P
10/295 20151101; B01D 46/0012 20130101; B22F 2999/00 20130101; B22F
2003/1056 20130101; B22F 2201/00 20130101 |
International
Class: |
B29C 64/35 20060101
B29C064/35; B29C 64/25 20060101 B29C064/25; B29C 64/245 20060101
B29C064/245; B29C 64/268 20060101 B29C064/268; B08B 5/04 20060101
B08B005/04; B33Y 10/00 20060101 B33Y010/00; B33Y 30/00 20060101
B33Y030/00; B33Y 40/00 20060101 B33Y040/00; B01D 46/00 20060101
B01D046/00 |
Claims
1. A system for printing a three-dimensional object, the system
comprising: a platform configured to support the three-dimensional
object during the printing; an enclosure configured to enclose the
three-dimensional object within an internal atmosphere comprising a
gas; and a filtering system configured to filter a gas-borne
material from a flow of the gas that exits the enclosure, the
filtering system comprising: a first canister operationally coupled
with the enclosure and comprising a first filter, a second canister
operationally coupled with the enclosure and comprising a second
filter, wherein each of the first and second filters is configured
to separate the gas-borne material from the flow of the gas, and at
least one valve configured to switch a direction of the flow of the
gas between the first canister and the second canister, which
switching facilitates uninterrupted separation of the gas-borne
material from the flow of the gas during the printing.
2. The system of claim 1, wherein during the printing, each of the
first and second filters is configured to separate the gas-borne
material from the flow of the gas.
3. The system of claim 1, wherein each of the first and second
filters is further configured to (i) separate the gas-borne
material from an external atmosphere, and/or (ii) separate the flow
of the gas from the external atmosphere.
4. The system of claim 1, wherein during the printing, each of the
first and second filters is further configured to (i) separate the
gas-borne material from an external atmosphere, and/or (ii)
separate the flow of the gas from the external atmosphere.
5. The system of claim 1, further comprising at least one pump
configured to supply a pumping force that drives the flow of the
gas through at least one of the first canister or the second
canister and back into the enclosure.
6. The system of claim 5, wherein the at least one pump is
configured to direct the flow of the gas from an outlet port of the
enclosure to an inlet port of the enclosure.
7. The system of claim 1, wherein the first and second canisters
are configured to substantially prevent a reactive agent in an
external atmosphere from reacting with the gas-borne material
within the first and second canisters respectively.
8. The system of claim 1, wherein the first canister is fluidly
coupled with the second canister.
9. The system of claim 1, wherein the enclosure is configured to
maintain the internal atmosphere at a positive pressure.
10. The system of claim 1, wherein the first filter and/or the
second filter comprises a High-efficiency particulate arrestance
filter (HEPA) filter.
11. The system of claim 1, wherein the first canister comprises a
first casing material and the second canister comprises a second
casing material, wherein at least one of the first casing material
and/or the second casing materials includes one or more layers.
12. The system of claim 1, wherein the at least one valve is
configured to reversibly decouple the first canister and/or the
second canister, from the enclosure.
13. The system of claim 1, wherein the gas-borne material comprises
at least one of debris, soot, or pre-transformed material.
14. The system of claim 1, further comprising at least one sensor
configured to detect (i) a reactive agent, or (ii) the gas-borne
material in the flow of the gas, which reactive agent is reactive
with the gas-borne material under one or more conditions prevailing
in the enclosure, first canister, and/or second canister.
15. The system of claim 14, wherein the reactive agent comprises
oxygen or water.
16. The system of claim 1, further comprising at least one sensor
configured to detect (i) a presence or absence of the first filter
and/or the second filter, (ii) a reactive species of the gas, (iii)
a velocity of the gas traveling, or (iv) a pressure, in the first
canister and/or the second canister.
17. The system of claim 16, wherein detect is (i) during the
printing, and/or (ii) a filtration process in the first canister
and/or the second canister.
18. The system of claim 16, wherein the at least one sensor is
coupled to at least one controller.
19. The system of claim 18, wherein the at least one controller is
configured to (i) control the flow of the gas, (ii) direct
replacement of the first filter and/or the second filter, and/or
(iii) direct decoupling of the first canister and/or the second
canister from the enclosure.
20. A method of printing a three-dimensional object, the method
comprising: (a) directing a flow of gas out of an enclosure that is
configured to enclose the three-dimensional object within an
internal atmosphere during printing; and (b) uninterruptedly during
the printing, using a filtering system operationally coupled to the
enclosure to filter a gas-borne material from the flow of gas out
of the enclosure, wherein using the filtering system comprises: (i)
filtering the gas-borne material in a first canister by passing the
flow of gas though a first filter disposed in the first canister,
(ii) directing the flow of gas from the first canister to a second
canister, and (iii) filtering the gas-borne material in the second
canister by passing the flow of gas though a second filter disposed
in the second canister to form a filtered gas.
21. The method of claim 20, further comprising facilitating
insertion of the filtered gas into the enclosure.
22. The method of claim 20, further comprising maintaining the flow
of gas at or below a velocity, temperature, and/or pressure
associated with a risk of a violent reaction between the gas-borne
material and a reactive agent (e.g., from an external
atmosphere).
23. The method of claim 20, further comprising causing at least one
pump to drive the flow of gas through the first canister gas and/or
second canister.
24. The method of claim 20, further comprising printing the
three-dimensional object, wherein the gas-borne material is
generated during the printing.
25. The method of claim 20, further comprising printing the
three-dimensional object by directing an energy beam at a material
bed comprising a pre-transformed material to form a transformed
material as part of the three-dimensional object.
26. The method of claim 20, wherein directing the flow of gas from
the first canister to a second canister comprises using at least
one valve to switch a direction of the flow of gas from the first
canister to the second canister.
27. The method of claim 20, further comprising using at least one
controller to (i) control the flow of gas, (ii) direct replacement
of the first filter and/or second filter, and/or (iii) direct
decoupling of the first canister and/or second canister from the
enclosure.
28. The method of claim 20, further comprising detecting (i) a
presence or absence of the first filter and/or second filters, (ii)
a reactive species in the flow of gas, (iii) a velocity of the flow
of gas, (iv) a pressure, or (v) a temperature of the flow of gas,
in the first canister and/or second canister.
29. The method of claim 28, wherein detecting is (i) during the
printing, and/or (ii) a filtration process in the first canister
and/or second canister.
Description
CROSS-REFERENCE
[0001] This application claims benefit of prior-filed U.S.
Provisional Patent Application Ser. No. 62/418,601, filed Nov. 7,
2016, titled "GAS FLOW DURING THREE-DIMENSIONAL PRINTING," U.S.
Provisional Patent Application Ser. No. 62/477,631, filed Mar. 28,
2017, titled "GAS FLOW DURING THREE-DIMENSIONAL PRINTING," U.S.
Provisional Patent Application Ser. No. 62/489,239, filed Apr. 24,
2017, titled "GAS FLOW IN THREE-DIMENSIONAL PRINTING," and U.S.
Provisional Patent Application Ser. No. 62/549,868, filed Aug. 24,
2017, titled "GAS FLOW IN THREE-DIMENSIONAL PRINTING," each of
which is entirely incorporated herein by reference.
BACKGROUND
[0002] Three-dimensional (3D) printing (e.g., additive
manufacturing) is a process for making a three-dimensional object
of any shape from a design. The design may be in the form of a data
source such as an electronic data source, or may be in the form of
a hard copy. The hard copy may be a two-dimensional representation
of a 3D object. The data source may be an electronic 3D model. 3D
printing may be accomplished through an additive process in which
successive layers of material are laid down one on top of another.
This process may be controlled (e.g., computer controlled, manually
controlled, or both). A 3D printer can be an industrial robot.
[0003] 3D printing can generate custom parts. A variety of
materials can be used in a 3D printing process including elemental
metal, metal alloy, ceramic, elemental carbon, or polymeric
material. In some 3D printing processes (e.g., additive
manufacturing), a first layer of hardened material is formed (e.g.,
by welding powder), and thereafter successive layers of hardened
material are added one by one, wherein each new layer of hardened
material is added on a pre-formed layer of hardened material, until
the entire designed three-dimensional structure (3D object) is
layer-wise materialized.
[0004] 3D models may be created with a computer aided design
package, via 3D scanner, or manually. The manual modeling process
of preparing geometric data for 3D computer graphics may be similar
to plastic arts, such as sculpting or animating. 3D scanning is a
process of analyzing and collecting digital data on the shape and
appearance of a real object (e.g., real-life object). Based on this
data, 3D models of the scanned object can be produced.
[0005] A number of 3D printing processes are currently available.
They may differ in the manner layers are deposited to create the
materialized 3D structure (e.g., hardened 3D structure). They may
vary in the material or materials that are used to materialize the
designed 3D object. Some methods melt, sinter, or soften material
to produce the layers that form the 3D object. Examples for 3D
printing methods include selective laser melting (SLM), selective
laser sintering (SLS), direct metal laser sintering (DMLS) or fused
deposition modeling (FDM). Other methods cure liquid materials
using different technologies such as stereo lithography (SLA). In
the method of laminated object manufacturing (LOM), thin layers
(made inter alia of paper, polymer, or metal) are cut to shape and
joined together.
[0006] The energy beam may be projected on a material bed to
transform a portion of the pre-transformed material to form the 3D
object. At times, debris (e.g., metal vapor, molten metal, or
plasma) may be generated in the enclosure (e.g., above the material
bed). The debris may float in the enclosure atmosphere. The
floating debris may alter at least one characteristic of the energy
beam (e.g., its power per unit area) during its passage through the
enclosure towards material bed. The debris may alter (e.g., damage)
to various components of the 3D printing system (e.g., optical
window). Some existing 3D printers establish cross flow of gas to
reduce the debris in the enclosure atmosphere. However, some of
these cross-flow solutions cause undesirable gas flow structures
(e.g., stagnation, recirculation of gas within the enclosure that
may lead to a steady state) that do not completely solve the debris
related issues. It may be desirable to establish a gas flow
solution that avoids the undesirable gas flow structures and allows
removal of debris from the enclosure atmosphere.
[0007] At times, during the 3D printing, various material forms
become gas-borne. The material forms may compromise (e.g., fine)
powder or soot. Some of the gas-borne material may be susceptible
to reaction with a reactive agent (e.g., an oxidizing agent). Some
of the gas-borne material may violently react (e.g., when coming
into contact with the reactive agent). At times, it may be
desirable to provide low leakage of the reactive agent (e.g.,
oxygen in the ambient atmosphere) into one or more segments of the
3D printer. At times, it may be desirable to isolate the interior
of one or more segments of the 3D printer from a harmful (e.g.,
violently reactive) level of the reactive agent (e.g., that is
present in the atmosphere external to the one or more segments of
the 3D printer). At times, it may be desirable to preserve a
non-reactive (e.g., inert) atmosphere in at least one segment of
the 3D printer (e.g., before, during and/or after the 3D
printing).
[0008] At times, gas-borne material may be collected within a
filtering mechanism. The gas-borne material may violently react
(e.g., ignite, flame and/or combust), when exposed to an atmosphere
comprising the reactive agent (e.g., an ambient atmosphere
comprising oxygen). It may be desirable to incorporate a filter
mechanism that is separated (e.g., isolated) from an external
(e.g., ambient) atmosphere comprising the reactive agent. It may be
desirable to incorporate a filter mechanism that maintains an inert
interior atmosphere around the filter, at least during the
filtering operation and/or disassembling of the filter from the
filtering mechanism. It may further be desirable to facilitate an
uninterrupted exchange of the filter in the filtering mechanism,
for example, in order to facilitate continuous separation of
gas-borne material from the recirculating gas in at least one or
more segments of the 3D printer during the 3D printing, for
example, when the filter clogs and requires exchange and/or
refurbishing. The present application describes ways of meeting at
least some of these desires.
SUMMARY
[0009] In one aspect, a system for three-dimensional (3D) printing
comprises: (a) an enclosure comprising a material bed, a first
enclosure side and a second enclosure side, wherein the first
enclosure side opposes the second enclosure side, wherein the
material bed is between the first enclosure side and the second
enclosure side, wherein between is inclusive; (b) an energy source
generating an energy beam that transforms a portion of the material
bed to a transformed material and defines a processing cone volume
disposed in the enclosure and above the material bed, wherein the
processing cone is an enclosure volume which the energy beam
occupies during the transforms; (c) a gas inlet opening through
which a gas flows into the processing cone volume, which gas inlet
opening is disposed in the first side; (d) a gas outlet opening
through which the gas flows out of the processing cone volume,
which gas outlet opening is disposed in the second side; and (e) at
least one controller that is operatively coupled to the enclosure,
energy beam, gas inlet, and gas outlet, and is programmed to (i)
direct the energy beam to transform at least a portion of the
material bed to a transformed material to form the 3D object, (ii)
direct the gas inlet opening to allow the gas to flow through the
processing cone, and (iii) direct the gas outlet opening to allow
an exit of the gas from the processing cone, wherein the gas flows
at least through the processing cone in a gas flow velocity
direction along a width of the enclosure, which gas flow velocity
direction remains unchanged during the gas flow at least through
the processing cone.
[0010] In some embodiments, the gas flow velocity direction does
not become zero (e.g., is different than zero, e.g., dose not stay
still, e.g., is not stagnant) during the gas flow at least through
the processing cone. In some embodiments, the second enclosure side
is comprised (e.g., included) in an aerodynamic shaped enclosure
portion. In some embodiments, the second enclosure side is
comprised in a wind tunnel. In some embodiments, the enclosure
comprises a wind tunnel that includes the second side. In some
embodiments, the gas flow velocity magnitude along the width of the
enclosure differs as the gas flows through at least the processing
cone, during at least the transformation. In some embodiments, the
gas flow velocity magnitude along the width of the enclosure is
substantially constant as the gas flows through at least the
processing cone, during at least the transformation. In some
embodiments, the gas flow velocity magnitude along at least one of
a height or a depth of the enclosure differs as the gas flows
through at least the processing cone, during at least the
transformation. In some embodiments, the gas flow velocity
direction along at least one of a height or a depth of the
enclosure differs as the gas flows through at least the processing
cone, during at least the transformation. In some embodiments, the
gas flow velocity magnitude along at least one of a height or a
depth of the enclosure is substantially constant as the gas flows
through at least the processing cone, during at least the
transformation. In some embodiments, the gas flow velocity
direction along at least one of a height or a depth of the
enclosure is substantially constant as the gas flows through at
least the processing cone, during at least the transformation. In
some embodiments, the gas flows through the processing cone is free
of at least one of (1) a recirculation, (2) flow stagnation, and
(3) static vortex of the gas. In some embodiments, the gas flows
through the processing cone in a smooth (e.g., undisturbed) flow.
In some embodiments, the gas flows through the processing cone in a
laminar flow. In some embodiments, the gas flows through the
processing cone in a non-turbulent flow. In some embodiments, the
gas flows through the processing cone in a non-stagnant flow. In
some embodiments, the gas flows through the processing cone in a
non-circulatory flow. In some embodiments, the first side comprises
an internal wall disposed between the material bed and the inlet
opening. In some embodiments, the internal wall comprises a filter.
In some embodiments, the filter is a High-Efficiency Particulate
Arrestance (TEPA) filter. In some embodiments, the internal wall
comprises an opening. In some embodiments, the internal wall
comprises a perforated plate. In some embodiments, the internal
wall comprises a flow aligning passage. In some embodiments, the
enclosure comprises a baffle between the inlet opening and the
internal wall. In some embodiments, the internal wall comprises a
ledge. In some embodiments, the internal wall comprises a ledge and
a perforated plate. In some embodiments, the gas flow may alter an
amount of debris in an atmosphere of the enclosure. In some
embodiments, alter is reduce. In some embodiments, the gas flow
removes an amount of debris in an atmosphere of the enclosure. In
some embodiments, remove is during at least a portion of the 3D
printing. In some embodiments, the gas flow flows during at least a
portion of the 3D printing. In some embodiments, at least a portion
of the 3D printing comprises during the operation of the energy
beam. In some embodiments, during the operation of the energy beam
comprises during the transforming. In some embodiments, the system
further comprises a recycling mechanism that treats (e.g., filters
and/or removes a reacting species (e.g., oxygen and/or humidity))
the gas that flows from the outlet opening. In some embodiments,
the recycling mechanism comprises a valve. In some embodiments, the
recycling mechanism is fluidly connected (e.g., allows flow
therethrough, e.g., flow of gas and/or liquid) to the outlet
opening. In some embodiments, the recycling mechanism is fluidly
connected to the inlet opening. In some embodiments, the recycling
mechanism filters the gas that enters the recycling mechanism, from
a debris. In some embodiments, the recycling mechanism removes a
reactive species from the gas that enters the recycling mechanism.
In some embodiments, the recycling mechanism outputs a gas with a
reduced amount of a debris. In some embodiments, the recycling
mechanism may output a gas with a reduced concentration of a
reactive species. In some embodiments, at least one controller is
further operatively coupled to the recycling mechanism and may
direct the recycling mechanism to recycle the gas that is evacuated
from the enclosure. In some embodiments, treating is during at
least a portion of the 3D printing. In some embodiments, treating
is continuous during at least a portion of the 3D printing. In some
embodiments, the recycling mechanism comprises a gas composition
sensor. In some embodiments, the recycling mechanism comprises a
pump. In some embodiments, the pump comprises a variable frequency
drive to control the flow of gas. In some embodiments, at least one
controller is a plurality of controllers. In some embodiments, at
least two of operations (i), (ii), and (iii) are performed by the
same controller. In some embodiments, at least two of operations
(i), (ii), and (iii) are performed by different controllers. In
some embodiments, the material bed comprises at least one
particulate material that is selected from the group consisting of
an elemental metal, metal alloy, ceramic, and an allotrope of
elemental carbon. In some embodiments, the 3D printing is additive
manufacturing. In some embodiments, the additive manufacturing
comprises selective laser sintering or selective laser melting. In
some embodiments, the energy beam comprises electromagnetic or
charged particle radiation. In some embodiments, the energy beam
comprises a laser beam. In some embodiments, the gas comprises
argon.
[0011] In another aspect, a method for generating a 3D object
comprising: (a) using an energy beam to transform a portion of a
material bed to a transformed material to form at least a portion
of the 3D object, wherein the material bed is disposed in an
enclosure, wherein the enclosure has a first enclosure side and a
second enclosure side that opposes the first enclosure side,
wherein the material bed is disposed between the first enclosure
side and the second enclosure side, wherein between is inclusive,
wherein the energy beam occupies a processing cone volume within
the enclosure and above the material bed during the using; and (b)
flowing a gas through the processing cone from the first enclosure
side, to the second enclosure side which gas exits the enclosure,
wherein the gas flow has a velocity direction along a width of the
enclosure, which velocity direction of the gas flow remains
unchanged during the gas flow through at least the processing
cone.
[0012] In some embodiments, the gas flows through at least the
processing cone without forming (at least in the processing cone
volume) at least one of (1) a recirculation, (2) flow stagnation,
and (3) static vortex, of the gas. In some embodiments, the gas
flows aerodynamically at least in the processing cone. In some
embodiments, the phrase "at least in the processing cone" comprises
a first enclosure volume that is from the first enclosure side to
the processing cone. In some embodiments, the phrase "at least in
the processing cone" comprises a second enclosure volume that is
from the processing cone to the second enclosure side. In some
embodiments, the phrase "at least in the processing cone" comprises
the entire processing chamber and/or enclosure volume. In some
embodiments, the method further comprises recycling the gas out of
(e.g., externally to) the enclosure from the second enclosure side.
In some embodiments, the method further comprises recycling the gas
out of the enclosure from the second enclosure side, and into the
enclosure through the first enclosure side. In some embodiments,
the method further comprises treating the gas that flows out of the
enclosure from the second enclosure side. In some embodiments,
treating comprises filtering the gas from a debris. In some
embodiments, treating comprises removing a reactive species from
the gas that flows from the outlet opening.
[0013] In another aspect, an apparatus for 3D printing comprising:
(a) an enclosure comprising a material bed, a first enclosure side
and a second enclosure side, wherein the first enclosure side
opposes the second enclosure side, wherein the material bed is
between the first enclosure side and the second enclosure side,
wherein between is inclusive; (b) an energy source generating an
energy beam that transforms a portion of the material bed to a
transformed material and defines a processing cone volume disposed
in the enclosure and above the material bed, wherein the processing
cone volume is at least a portion of the enclosure volume that the
energy beam occupies during the transforms; (c) a gas inlet opening
through which a gas flows into the processing cone volume, which
gas inlet opening is disposed in the first side; and (d) a gas
outlet opening through which the gas flows out of the processing
cone volume, which gas outlet opening is disposed in the second
side, which gas flow has a velocity direction, wherein the
enclosure has an internal shape that is configured to allow the
velocity direction of the gas flow along a width of the enclosure
to remain unchanged during the gas flow through at least the
processing cone.
[0014] In another aspect, an apparatus for 3D printing comprising
at least one controller that is programmed to perform operations:
operation (a) direct an energy beam from an energy source to a
material bed to transform at least a portion of the material bed to
a transformed material and form the 3D object, wherein the material
bed is disposed in an enclosure, wherein the enclosure has a first
enclosure side and a second enclosure side opposing the first
enclosure side, wherein the material bed is disposed between the
first opposing side and the second opposing side, wherein between
is inclusive; and operation (b) direct a gas flow from the first
enclosure side through a processing cone, to the second enclosure
side, which processing cone is an enclosure volume that the energy
beam occupies during the transform, which gas flow has a velocity
direction, wherein the velocity direction of the gas flow along a
width of the enclosure remains unchanged during the gas flow
through at least the processing cone.
[0015] In some embodiments, the flow of gas through at least the
processing cone volume is devoid of at least one of (1) a
recirculation, (2) flow stagnation, and (3) static vortex. In some
embodiments, at least one controller is a multiplicity of
controllers and wherein at least two of operations (a), and (b) is
directed by the same controller. In some embodiments, at least one
controller is a multiplicity of controllers and wherein at least
two of operations (a), and (b) is directed by the different
controllers. In some embodiments, the controller directs a first
valve to control the gas that enters the first enclosure side. In
some embodiments, the controller directs a second valve to control
the gas that exits the second enclosure side. In some embodiments,
the controller controls at least one of the makeup, density,
trajectory, and velocity of the gas that enters the enclosure. In
some embodiments, at least in the processing cone, the trajectory
of a flow of the gas is linear. In some embodiments, the trajectory
is linear in one or more of: the height, depth, and width of the
enclosure. In some embodiments, at least in the processing cone,
the trajectory of a flow of the gas is smooth. In some embodiments,
the trajectory is smooth in one or more of: the height, depth, and
width of the enclosure.
[0016] In another aspect, a method for printing a 3D object
comprises, during the 3D printing: (a) flowing at least one gas at
a velocity through a gas flow mechanism, which at least one gas is
inserted to the gas flow mechanism through an opening in the gas
flow mechanism, which gas is inert with respect to the material
used or produced in a 3D printing of the 3D object; (b) maintaining
the pressure of the at least one gas in the gas flow mechanism to
above an ambient atmospheric pressure; and (c) maintaining a low
level of a reactive agent in the gas flow mechanism, which low
level is below a violent reaction level of the reactive agent with
the material used or produced during the 3D printing, wherein the
material used or produced during the 3D printing reacts violently
at an ambient atmosphere flowing at the velocity.
[0017] In some embodiments, the violent reaction is an exothermic
reaction. In some embodiments, the violent reaction comprises
combustion, ignition, or flaming. In some embodiments, the gas flow
mechanism comprises a channel, chamber, valve, or a pump. In some
embodiments, maintaining the pressure comprises limiting occurrence
of a negative pressure with respect to the ambient atmospheric
pressure in at least one section of the gas flow mechanism. In some
embodiments, at least one section of the gas flow mechanism
comprises an area adjacent to the pump. In some embodiments, at
least one section of the gas flow mechanism comprises an area
behind the pump relative to the direction of gas flow. In some
embodiments, maintaining the pressure comprises raising the
pressure of the at least one gas in the gas flow mechanism. In some
embodiments, maintaining the pressure comprises purging of at least
one reactive agent from the gas flow mechanism. In some
embodiments, purging comprises opening, closing, or adjusting one
or more valves. In some embodiments, purging comprises opening at
least one inlet-purge-valve to insert at least one gas into the gas
flow mechanism, and opening at least one outlet-purge-valve to
evacuate at least one reactive agent from the gas flow mechanism
and reach a low level of the reactive agent in the gas flow
mechanism. In some embodiments, a least one gas is an inert gas
with respect to the material used or produced in the 3D printing.
In some embodiments, the method further comprises opening at least
one inlet modulating-valve and at least one outlet modulating-valve
to maintain or reduce the low level of the reactive agent in the
gas flow mechanism. In some embodiments, maintaining or reducing
the low level of the reactive agent in the gas flow mechanism
comprises inserting at least one gas into the gas flow mechanism
through the inlet modulating-valve, and expelling the reactive
agent through the outlet modulating valve. In some embodiments, at
least two of: the inlet purge-valve, outlet purge-valve, inlet
modulating-valve, and outlet modulating-valve have the same cross
section. In some embodiments, at least two of the inlet
purge-valve, outlet purge-valve, inlet modulating-valve, and outlet
modulating-valve have a different cross section. In some
embodiments, the modulating-valve has a smaller cross section than
the purge-valve. In some embodiments, the modulating-valve
facilitates a slow mass flow of gas into at least a segment of the
gas flow mechanism. In some embodiments, purging is performed
within at least one segment of the gas flow mechanism. In some
embodiments, at least two segments of the gas flow mechanism are
purged simultaneously. In some embodiments, at least two segments
of the gas flow mechanism are purged sequentially. In some
embodiments, purging is performed independently within one or more
segments of the gas flow mechanism. In some embodiments, the one or
more segments of the gas flow mechanism is isolated with respect to
their gas flow. In some embodiments, purging is performed
collectively within two or more segments of the gas flow mechanism.
In some embodiments, purging is switched from being performed
independently to being performed collectively, and vice-versa. In
some embodiments, switching is based on a reactive agent level
threshold. In some embodiments, purging includes engaging and/or
disengaging an operation of a pump. In some embodiments, purging
comprises separating at least one segment of the gas flow mechanism
and purging it separately. In some embodiments, purging comprises
flowably separating at least one segment of the gas flow mechanism,
and purging it separately. In some embodiments, purging separately
excludes using a pump. In some embodiments, purging comprises
coupling at least two segments of the gas flow mechanism and
purging the at least two segments collectively. In some
embodiments, purging comprises flowably coupling the at least two
segments of the gas flow mechanism and purging the at least two
segments collectively. In some embodiments, purging the at least
two segments collectively excludes using a pump. In some
embodiments, coupling at least two segments of the gas flow
mechanism comprises the processing chamber and a gas filter. In
some embodiments, the reactive agent comprises oxygen, water,
carbon dioxide, or nitrogen. In some embodiments, the at least one
gas comprises an inert gas with respect to the material used or
produced during the 3D printing. In some embodiments, the at least
one gas comprises a noble gas. In some embodiments, the at least
one gas comprises Argon. In some embodiments, the material used
during the 3D printing comprises an elemental metal, metal alloy,
ceramic, an allotrope of elemental carbon, polymer, or a resin. In
some embodiments, the material used during the 3D printing
comprises an elemental metal, metal alloy, ceramic, or an allotrope
of elemental carbon. In some embodiments, the material used during
the 3D printing comprises a particulate material. In some
embodiments, the material produced during the 3D printing comprises
soot, and/or a transformed material. In some embodiments, the
transformed material comprises a molten material (e.g., that
subsequently solidified). In some embodiments, the gas flow
mechanism comprises a processing chamber in which the 3D object is
printed during the 3D printing. In some embodiments, maintaining in
operation (c) comprises allowing a flow rate of the reactive agent
into the gas flow mechanism of at most five cubic centimeter per
minute. In some embodiments, maintaining in operation (c) comprises
allowing a flow rate of the reactive agent into the gas flow. In
some embodiments, maintaining in operation (c) comprises allowing a
flow rate of the reactive agent into the gas flow mechanism of at
most one tenth of a cubic centimeter per minute. In some
embodiments, maintaining in operation (c) comprises allowing a flow
rate of the reactive agent into the gas flow mechanism of at most
one hundredth of a cubic centimeter per minute.
[0018] In another aspect, a system used in 3D printing of at least
one 3D object comprises: a gas flow mechanism, which gas flow
mechanism comprises an opening; and at least one controller that is
operatively coupled to the gas flow mechanism, which at least one
controller is programmed to direct performance of the following
operations during the 3D printing: operation (i) direct flowing at
least one gas at a velocity through the gas flow mechanism, which
at least one gas is inserted to the gas flow mechanism through the
opening, which gas is inert with respect to the material used or
produced in the 3D printing of the 3D object, operation (ii) direct
maintaining a pressure of the at least one gas in the gas flow
mechanism to above an ambient atmospheric pressure, and operation
(iii) direct maintaining a low level of a reactive agent in the gas
flow mechanism, which low level is below a violent reaction level
of the reactive agent with the material used or produced during the
3D printing, wherein the material used or produced during the 3D
printing reacts violently at an ambient atmosphere that flows at
the velocity.
[0019] In some embodiments, the opening is configured to facilitate
transporting the at least one gas to or from the gas flow
mechanism. In some embodiments, the system further comprises an
energy source configured to generate an energy beam that transforms
the material used in 3D printing for printing of the 3D object, and
wherein the controller is operatively coupled to the energy beam
and directs the energy beam to transform the material used in 3D
printing for printing of the 3D object. In some embodiments, the
violent reaction is an exothermic reaction. In some embodiments,
the violent reaction comprises combustion, ignition, or flaming. In
some embodiments, the gas flow mechanism comprises a channel,
chamber, valve, or a pump. In some embodiments, the system further
comprises one or more valves operatively coupled to the gas flow
mechanism. In some embodiments, the one or more valves are
configured to facilitate maintaining a low level of a reactive
agent in the gas flow mechanism. In some embodiments, the at least
one controller is operatively coupled to the one or more valves,
and is further configured to direct performance of operation (iv)
direct the at least one valve to open or close. In some
embodiments, at least one controller is configured to direct the
timing and/or degree at which the at least one valve opens or
closes. In some embodiments, at least two of operations (i), (ii),
(iii), and (iv) are directed by the same controller. In some
embodiments, at least two of operations (i), (ii), (iii), and (iv)
are directed by the different controllers. In some embodiments, the
system further comprises one or more sensors operatively coupled to
the gas flow mechanism. In some embodiments, at least one
controller is operatively coupled to the one or more sensors. In
some embodiments, the controller considers the signal when
performing one or more of operations (i), (ii), (iii), and (iv). In
some embodiments, the sensor is configured to facilitate sensing a
temperature, pressure, reactive agent level, and/or the velocity,
of the at least one gas within the gas flow mechanism.
[0020] In another aspect, an apparatus used in a 3D printing of at
least one 3D object comprises at least one controller that is
programmed to perform the following operations: operation (i)
direct flowing at least one gas at a velocity through a gas flow
mechanism, which at least one gas is inserted to the gas flow
mechanism through an opening in the gas flow mechanism, which gas
is inert with respect to the material used or produced in a 3D
printing of the 3D object; operation (ii) direct maintaining a
pressure of the at least one gas in the gas flow mechanism to above
an ambient atmospheric pressure; and operation (iii) direct
maintaining a low level of a reactive agent in the gas flow
mechanism, which low level is below a violent reaction level of the
reactive agent with the material used or produced during the 3D
printing, wherein the material used or produced during the 3D
printing reacts violently at an ambient atmosphere flowing at the
velocity.
[0021] In some embodiments, the two or more of operation (i), (ii),
and (iii) are directed by the same controller. In some embodiments,
the at least one controller is a plurality of controllers. In some
embodiments, two or more of operation (i), (ii), and (iii) are
directed by different controllers. In some embodiments, the
controller is operatively coupled to an energy beam and directs the
energy beam to transform the material used in 3D printing for
printing the 3D object. In some embodiments, the violent reaction
is an exothermic reaction. In some embodiments, the violent
reaction comprises combustion, ignition, or flaming. In some
embodiments, the at least one controller is operatively coupled to
one or more valves and is further configured to direct performance
of operation (iv): direct the at least one valve to open or close.
In some embodiments, the one or more valves is configured to
facilitate maintaining a low level of a reactive agent in the gas
flow mechanism. In some embodiments, the at least one controller is
configured to direct the timing and/or degree at which the at least
one valve opens or closes. In some embodiments, at least two of
operations (i), (ii), (iii), and (iv) are directed by the same
controller. In some embodiments, at least two of operations (i),
(ii), (iii), and (iv) are directed by the different controllers. In
some embodiments, the apparatus further comprises one or more
sensors operatively coupled to the gas flow mechanism. In some
embodiments, the at least one controller is operatively coupled to
the one or more sensors. In some embodiments, the at least one
controller considers input from the one or more sensors when
performing at least one of operations (i), (ii), (iii), and (iv).
In some embodiments, the one or more sensors is configured sense a
temperature, pressure, reactive agent level, and/or the velocity,
of the at least one gas within the gas flow mechanism. In some
embodiments, the at least one controller considers the input using
feedback or close loop control. In some embodiments, the at least
one controller is further configured to direct reducing a level of
a reactive agent in the gas flow mechanism.
[0022] In another aspect, a computer software product for 3D
printing of at least one 3D object, comprises a non-transitory
computer-readable medium in which program instructions are stored,
which instructions, when read by a computer, cause the computer to
perform operations comprising: operation (i) direct flowing at
least one gas at a velocity through a gas flow mechanism, which at
least one gas is inserted to a gas flow mechanism through an
opening in the gas flow mechanism, which gas is inert with respect
to a material used or produced in a 3D printing of the 3D object;
operation (ii) direct maintaining the pressure of the at least one
gas in the gas flow mechanism to above an ambient atmospheric
pressure; and operation (iii) direct maintaining a low level of a
reactive agent in the gas flow mechanism, which low level is below
a violent reaction level of the reactive agent with the material
used or produced during the 3D printing, wherein the material used
or produced during the 3D printing reacts violently at an ambient
atmosphere flowing at the velocity.
[0023] In another aspect, a method for generating at least one 3D
object (e.g., a 3D object) comprises: (a) isolating a first filter
from an external atmosphere, which external atmosphere comprises a
reactive agent that reacts with the material used or generated
during a 3D printing of the 3D object; (b) separating during the 3D
printing a gas-borne material that is used or generated during the
3D printing, from a recirculating gas through the first filter,
which recirculating gas recirculates through a gas flow mechanism
comprising a processing chamber in which the 3D object is printed,
which recirculating gas flows at a velocity in the processing
chamber; (c) isolating a second filter from the external
atmosphere, wherein the gas flow mechanism comprises the first
filter or the second filter; and (d) switching from the first
filter to the second filter while continuously and uninterruptedly
separating the gas-borne material from the recirculating gas
through the gas flow mechanism.
[0024] In some embodiments, the reactive agent reacts with the
material that is used or generated during 3D printing, when
translating at the velocity. In some embodiments, isolating the
first filter from the external atmosphere comprises encasing it in
a first canister. In some embodiments, isolating the second filter
from the external atmosphere comprises encasing it in a second
canister. In some embodiments, isolating the first filter from the
external atmosphere comprises encasing it in a first canister,
isolating the second filter from the external atmosphere comprises
encasing it in a second canister, and the gas flow mechanism
comprises the first canister and the second canister. In some
embodiments, switching from the first filter to the second filter
comprises switching from the first canister to the second canister.
In some embodiments, isolating comprises reducing influx of the
external atmosphere. In some embodiments, isolating comprises
facilitating penetration of the external atmosphere. In some
embodiments, the first canister comprises a non-reactive, inert,
and/or noble-gas interior atmosphere. In some embodiments, the
non-reactivity is relative to a reaction with the material used or
produced during the 3D printing. In some embodiments, the second
canister comprises a non-reactive, inert, and/or noble-gas interior
atmosphere. In some embodiments, non-reactive is relative to a
reaction with the material used or produced during the 3D printing.
In some embodiments, switching comprises determining clogging of
the first filter. In some embodiments, switching comprises
determining unsafe use of the first filter. In some embodiments,
switching comprises determining presence and safe use of the second
filter.
[0025] In another aspect, an apparatus for 3D printing of at least
one 3D object, comprises: a first canister comprising a first
filter, which first filter is configured to separate gas-borne
material from a recirculating gas at least during the 3D printing,
which first canister comprises a first casing that separates the
first filter from an external atmosphere comprising a reactive
agent, wherein the gas-borne material comprises a material used or
produced during the 3D printing; a second canister comprising a
second filter, which second filter is configured to separate the
gas-borne material from the recirculating gas which second canister
comprises a second casing that separates the filter from the
external atmosphere comprising the reactive agent; and a gas flow
mechanism comprises the first canister, the second canister, or a
processing chamber where the 3D object is printed during the 3D
printing, which gas flow mechanism is configured to recirculate gas
from the processing chamber to the first canister and/or to the
second canister.
[0026] In some embodiments, the first canister comprises a first
casing configured to prevent combustion of the reactive agent with
the gas-borne material. In some embodiments, the second canister
comprises a second casing configured to prevent combustion of the
reactive agent with the gas-borne material. In some embodiments,
the first canister comprises a first casing that is configured to
prevent combustion of the reactive agent with the gas-borne
material, the second canister comprises a second casing configured
to prevent combustion of the reactive agent with the gas-borne
material, and wherein the first casing is of the same type as the
second casing. In some embodiments, the first canister comprises a
first casing that is configured to prevent combustion of the
reactive agent with the gas-borne material, the second canister
comprises a second casing configured to prevent combustion of the
reactive agent with the gas-borne material, and the first casing is
different from the second casing. In some embodiments, the first
casing is different from the second casing by its material type,
casing wall structure, and/or casing shape. In some embodiments,
the first casing and/or second casing comprises (i) a material
type, (ii) casing wall structure, or (iii) casing shape, that is
configured to reduce a flow of the external atmosphere into the
first canister or second canister respectively. In some
embodiments, the wall structure is configured to isolate the
external atmosphere from an interior of the second casing and/or
first casing respectively. In some embodiments, the wall structure
comprises one or more layers. In some embodiments, the layers
comprise a solid layer, a liquid layer, a semi-solid layer, or a
gas-layer. In some embodiments, the gas-layer is a reduced pressure
(e.g., vacuum) gas-layer. In some embodiments, the first casing and
the second casing is fluidly (e.g., flowingly, or permitting flow)
and/or reversibly coupled to the processing chamber through at
least one valve. In some embodiments, the at least one valve
decouples (e.g., separate, disengage) the first canister and/or the
second canister from the processing chamber. In some embodiments,
the decoupling of the first canister and/or the second canister
from the processing chamber is configured to facilitate
recirculation of the gas at least in the processing chamber. In
some embodiments, the decoupling of the first canister or the
second canister from the processing chamber is configured to
facilitate continuous filtering of the gas-borne material during
the 3D printing. In some embodiments, the first canister comprises
a first valve. In some embodiments, the first valve can couple the
first canister to the processing chamber. In some embodiments, the
second canister comprises a second valve. In some embodiments, the
second valve couples the second canister to the processing
chamber.
[0027] In another aspect, a system used in 3D printing of at least
one 3D object, comprises: a first canister comprising a first
filter, wherein the first filter is configured to separate at least
one gas from a gas-borne material that is used or generated during
a 3D printing of the at least one 3D object, wherein the external
atmosphere comprises a reactive agent that violently reacts with
the gas-borne material, wherein the first canister is configured to
separate the first filter from an external atmosphere, wherein the
at least one gas does not react violently with the reactive agent;
a second canister comprising a second filter, wherein the second
filter is configured to separate the at least one gas from the
gas-borne material, wherein the second canister is configured to
separate the second filter from the external atmosphere to lower
the possibility of violent reaction between the gas-borne material
and the reactive agent; a gas flow mechanism comprising the first
canister, or the second canister, which gas flow mechanism is
configured to accommodate the at least one gas; and at least one
controller that is operatively coupled to the first canister, and
the second canister, which at least one controller is programmed to
separately or collectively direct performance of the following
operations at least during the 3D printing: operation (i) direct
using the first filter to separate the gas-borne material from the
at least one gas that recirculates through the gas flow mechanism,
and operation (ii) direct switching from (a) using the first filter
to separate the at least one gas from the gas-borne material to (b)
using the second filter to separate the at least one gas from the
gas-borne material, which switching facilitates continuous and
uninterrupted separation of the gas-borne material from the at
least one gas.
[0028] In some embodiments, the system further comprises a
processing chamber where the at least one 3D object is printed. In
some embodiments, the gas flow mechanism comprises the processing
chamber. In some embodiments, the at least one gas flows at a
velocity (e.g., a pre-determined velocity) in the first canister
and/or second canister. In some embodiments, lowering the
possibility of violent reaction between the gas-borne material and
the reactive agent is when the gas borne material and/or reactive
agent flows (e.g., maintained below or) at the velocity. In some
embodiments, the violent reaction comprises combustion, flaming, or
ignition. In some embodiments, the first canister is fluidly
coupled to the second canister. In some embodiments, the first
canister is fluidly coupled to the processing chamber. In some
embodiments, the second canister is fluidly coupled to the
processing chamber. In some embodiments, direct switching comprises
direct altering the status of one or more valves. In some
embodiments, direct switching comprises direct altering the status
of one or more valves. In some embodiments, direct switching
comprises disconnecting the first canister with the processing
chamber. In some embodiments, disconnecting comprises disconnecting
the flow of the at least one gas and/or gas-borne material. In some
embodiments, direct switching comprises connecting the second
canister with the processing chamber. In some embodiments,
connecting comprises connecting the flow of the at least one gas
and/or gas-borne material. In some embodiments, at least one
controller is operatively coupled to the processing chamber.
[0029] In another aspect, an apparatus for 3D printing of at least
one 3D object comprises at least one controller that is programmed
to collectively or separately perform the following operations at
least during the 3D printing: operation (i) direct using a first
filter to separate a gas-borne material from at least one gas that
recirculates through a gas flow mechanism, which first filter is
housed in a first canister that is configured to separate the first
filter from an external atmosphere, wherein the gas-borne material
is used or produced during the 3D printing, which gas flow
mechanism comprises the first canister, wherein the external
atmosphere comprises a reactive agent that violently reacts with
the gas-borne material, wherein the at least one gas does not react
violently with the reactive agent; and operation (ii) direct
switching from (a) using the first filter to separate the at least
one gas from the gas-borne material to (b) using a second filter to
separate the at least one gas from the gas-borne material, which
switching facilitates continuous and uninterrupted separation of
the gas-borne material from the at least one gas, wherein the
second filter is housed in a second canister that is configured to
separate the second filter from the external atmosphere, wherein
the gas flow mechanism comprises the second canister.
[0030] In some embodiments, the gas flow mechanism comprises a
processing chamber in which the 3D object is printed during the 3D
printing. In some embodiments, the processing chamber is
operatively coupled to first canister, the second canister, or both
the first canister and the second canister. In some embodiments,
the processing chamber is fluidly connected to first canister, the
second canister, or both the first canister and the second
canister. In some embodiments, the at least one controller is
programmed to direct an energy beam to transform the material used
for the 3D printing to transform to print the 3D object.
[0031] In another aspect, a computer software product for 3D
printing of at least one 3D object, comprising a non-transitory
computer-readable medium in which program instructions are stored,
which instructions, when read by a computer, cause the computer to
perform operations comprises: operation (i) direct using a first
filter to separate a gas-borne material from at least one gas that
recirculates through a gas flow mechanism, which first filter is
housed in a first canister that is configured to separate the first
filter from an external atmosphere, wherein the gas-borne material
is used or produced during the 3D printing, which gas flow
mechanism comprises the first canister, wherein the external
atmosphere comprises a reactive agent that violently reacts with
the gas-borne material, wherein the at least one gas does not react
violently with the reactive agent; and operation (ii) direct
switching from (a) using the first filter to separate the at least
one gas from the gas-borne material to (b) using a second filter to
separate the at least one gas from the gas-borne material, which
switching facilitates continuous and uninterrupted separation of
the gas-borne material from the at least one gas, wherein the
second filter is housed in a second canister that is configured to
separate the second filter from the external atmosphere, wherein
the gas flow mechanism comprises the second canister.
[0032] In another aspect, a system for printing a 3D object
comprises: an energy source configured to generate an energy beam
for transforming at least a portion of a pre-transformed material
to a transformed material; a platform configured to support the 3D
object; and an enclosure configured to enclose at least a portion
of the platform during a printing operation, the enclosure (I) is
operatively coupled to, or comprises a gas inlet portion at a first
enclosure side and (II) is operatively coupled to, or comprises a
gas outlet portion at a second enclosure side, wherein the gas
inlet portion is configured to direct a flow of gas over a target
surface that is (i) adjacent to the platform or (ii) comprises an
exposed surface of the platform, and to the gas outlet portion,
which gas inlet portion is configured to alter at least one
characteristic of the flow of gas.
[0033] In some embodiments, altering the at least one
characteristic of the flow of gas comprises altering a shape, a
volume, a velocity, a direction, or an alignment of the flow of
gas. In some embodiments, the platform is configured to vertically
translate. In some embodiments, the platform is configured to
vertically translate during the printing. In some embodiments, the
target surface comprises the exposed surface of the 3D object. In
some embodiments, the pre-transformed material is part of a
material bed that is disposed on the platform. In some embodiments,
the target surface comprises an exposed surface of the material
bed. In some embodiments, the gas inlet portion is configured to
direct the flow of gas in a direction that is substantially
parallel to the target surface. In some embodiments, the system may
be configured for printing a plurality of 3D objects. In some
embodiments, the system may be configured for printing a plurality
of 3D objects in the printing operation. In some embodiments, the
first enclosure side faces the second enclosure side. In some
embodiments, first enclosure side is disposed in an opposite
direction to the second enclosure side. In some embodiments, the
gas inlet portion is configured to direct the flow of gas in a
first direction, wherein the gas inlet portion is configured to
reduce a second flow of gas in a second direction that is
substantially orthogonal to the first direction. In some
embodiments, the enclosure comprises a window configured to allow
the energy beam to pass therethrough. In some embodiments, the
window is located vertically with respect to the platform. In some
embodiments, the gas inlet portion is configured to direct the flow
of gas in a substantially parallel to an average plane of the
window. In some embodiments, the gas inlet portion comprises at
least one baffle having at least one surface that is (e.g.,
substantially) non-parallel to the exposed surface of the platform.
In some embodiments, the flow of gas over the target surface is
substantially in accordance with a first directional component,
wherein the at least one baffle is configured to increase a second
directional component of the flow of gas within the gas inlet
portion, wherein the second directional component is (e.g.,
substantially) non-parallel with the first directional component.
The enclosure is configured to hold a positive pressure. In some
embodiments, the flow of gas over the target surface is
substantially in an X direction. In some embodiments, the at least
one baffle is configured to increase Z and/or Y directional
components of the flow of gas through the gas inlet portion. In
some embodiments, the gas inlet portion comprises an elongated
opening defined by a width and height. In some embodiments, a
width-to-height ratio of the elongated opening is at least about 1,
1.5, 2, 5, 10, 15, 20, or 50. In some embodiments, the gas inlet
portion comprises a first outlet port. In some embodiments, the
first outlet port includes a perforated plate that channels the
flow of gas through the first outlet port. In some embodiments, the
gas inlet portion comprises a plurality of channels that channel
the flow of gas through the first outlet port. In some embodiments,
the plurality of channels are within a flow straightener (e.g.,
flow aligner). In some embodiments, the first outlet port includes
a perforated plate that channels the flow of gas through the first
outlet port. In some embodiments, the gas outlet portion has an
aerodynamic shape configured to reduce gas turbulence within a
processing chamber of the enclosure. In some embodiments, a path of
the energy beam in a volume of a processing chamber of the
enclosure defines a processing cone. In some embodiments, the gas
outlet portion comprises a second inlet port and a second outlet
port, wherein the gas outlet portion is configured to reduce
backflow, turbulence, standing vortex, or any combination thereof,
at least in the processing cone. In some embodiments, channeling
the flow of gas comprises aligning the flow of gas. In some
embodiments, the gas inlet portion is separated from a processing
chamber of the enclosure by a first wall. In some embodiments, the
gas outlet portion is separated from the processing chamber of the
enclosure by a second wall. In some embodiments, the system
comprises an optical mechanism that is configured to control a
trajectory of the energy beam through the enclosure. In some
embodiments, at least a portion of the optical mechanism is
enclosed in a casing. the casing is purged by a purging gas flow.
In some embodiments, the casing is leaky (e.g., to facilitate exit
of the flow of gas). In some embodiments, the energy source is a
first energy source and the energy beam is a first energy beam. In
some embodiments, the system includes a second energy source
configured to generate a second energy beam. In some embodiments,
the second energy source is configured to direct the second energy
beam at the target surface. In some embodiments, the second energy
beam has at least one different energy characteristic than the
first energy beam. In some embodiments, the second energy beam has
at least one energy characteristic that is the same as that of the
first energy beam. In some embodiments, the system further
comprises a window configured to allow the energy beam to pass
therethrough, and a recessed portion that supports the window and
that includes a wall that defines a volume. In some embodiments,
the wall includes an outlet opening arranged to direct a purging
flow of gas into the volume. In some embodiments, the outlet
opening is arranged to direct the flow of gas away from the window.
In some embodiments, away from the window comprises toward a
processing chamber of the enclosure. In some embodiments, the
outlet opening is arranged to direct the flow of gas in a direction
substantially parallel to a surface of the window. In some
embodiments, the system further comprises a gas recycling system
comprising: a filtration system that filters debris from the flow
of gas exiting the gas outlet portion. In some embodiments, the
system further comprises a gas recycling system comprising: at
least one pump configured to control a pressure of the flow of gas.
In some embodiments, controlling the pressure comprises regulating
the pressure. In some embodiments, controlling the pressure
comprises increasing the pressure. In some embodiments, the system
comprises a window housing having a window and an outlet opening,
wherein the gas recycling system is configured to supply clean gas
to the outlet opening. In some embodiments, the gas inlet portion
is configured to direct the flow of gas toward a surface of a
material bed of the pre-transformed material. In some embodiments,
the gas inlet portion comprises a backflow gas outlet portion
configured to allow a backflow of gas to exit the enclosure. In
some embodiments, the backflow gas outlet portion is disposed
proximate to a gas inlet port of the gas inlet portion.
[0034] In another aspect, a method for printing a 3D object
comprises: (a) directing a flow of gas through an enclosure from an
inlet portion to an outlet portion, which flow of gas is above a
target surface; (b) altering at least one characteristic of the
flow of gas as it flows through the inlet portion; and (c)
directing an energy beam toward a platform to transform a
pre-transformed material to a transformed material as part of the
printing of the 3D object, wherein the platform is disposed in the
enclosure.
[0035] In some embodiments, the flow of gas above the target
surface is in accordance with a first directional component, the
method further comprising increasing a second directional component
of the flow of gas within the inlet portion, the second directional
component being (e.g., substantially) non-parallel with respect to
the first directional component. In some embodiments, the flow of
gas above the target surface is in accordance with a first
directional component, the method further comprising increasing the
flow of gas in the first directional component by directing the
flow of gas through a plurality of channels within the inlet
portion. In some embodiments, one or more controllers collectively
or separately are programed to direct the operations of (a), (b)
and (c). In some embodiments, during (c), an insubstantial amount
of debris affects the printing of the three-dimensional3D object.
In some embodiments, insubstantial comprises negligent,
non-material, inconsequential, trivial, or negligible. In some
embodiments, insubstantial is to a detectable degree. In some
embodiments, during operation (c) an insubstantial amount of debris
interacts with the energy beam. In some embodiments, during
operation (c) an insubstantial amount of debris accumulates on
and/or obstructs a window through which the energy beam travels. In
some embodiments, the flow of gas is a primary flow of gas. In some
embodiments, the method further comprises directing a secondary
flow of gas within a volume of a recessed portion that is
configured to support the window. In some embodiments, altering the
at least one characteristic of the flow of gas comprises altering a
shape, a volume, a velocity, a direction, or an alignment of the
flow of gas. In some embodiments, vertically translating the
platform is during the printing. In some embodiments, the target
surface is an exposed surface of the 3D object. In some
embodiments, the pre-transformed material is part of a material bed
that is disposed on the platform. In some embodiments, the target
surface comprises an exposed surface of the material bed. In some
embodiments, the method further comprises printing a plurality of
3D objects. In some embodiments, directing the flow of gas over the
target surface is while at least the portion of the pre-transformed
material is being transformed to the transformed material. In some
embodiments, the inlet portion directs the flow of gas in a
direction that is substantially parallel to the target surface. In
some embodiments, the inlet portion directs the flow of gas in a
first direction and alters at least one characteristic of the flow
of gas in a second direction. In some embodiments, the second
direction is substantially orthogonal to the first direction. In
some embodiments, directing the energy beam at the target surface
comprises directing the energy beam through a window that is
located (I) vertically with respect to the platform and/or (II) in
a wall of the enclosure that faces the platform. In some
embodiments, the flow of gas over the target surface is
substantially in an X direction. In some embodiments, the inlet
portion comprises baffles that increase Z and/or Y directional
components of the flow of gas through the inlet portion. In some
embodiments, the inlet portion comprises an elongated opening
defined by a width and height, wherein a width-to-height ratio of
the elongated opening is at least about 1, 1.5, 2, 5, 10, 15, 20,
or 50. In some embodiments, the inlet portion comprises an outlet
port comprising a plurality of channels that aligns the flow of gas
through the outlet port. In some embodiments, the outlet port
comprises a perforated plate. In some embodiments, the inlet
portion is separated from a processing chamber of the enclosure by
a first wall. In some embodiments, the enclosure comprises a
processing chamber. In some embodiments, the method further
comprising directing the flow of gas into the processing chamber
via the inlet portion that is (i) a part of the processing chamber
or (ii) is operatively coupled to the processing chamber. In some
embodiments, the method further comprising directing the flow of
gas out of the processing chamber via a gas outlet portion that is
(i) a part of the processing chamber or (ii) is operatively coupled
to the processing chamber. In some embodiments, the gas outlet
portion has an aerodynamic shape that reduces a turbulence of the
flow of gas within the processing chamber. In some embodiments,
directing the energy beam at the target surface comprises
controlling a trajectory of the energy beam through the enclosure
using an optical mechanism. In some embodiments, the method further
comprises purging a casing with a purging gas flow. In some
embodiments, at least a portion of the optical mechanism is
enclosed by the casing. In some embodiments, the casing is leaky
(e.g., to facilitate exit of the purging gas flow from the casing).
In some embodiments, the energy beam is a first energy beam. In
some embodiments, the method further comprises directing a second
energy beam toward the platform. In some embodiments, the second
energy beam has a different energy characteristic than the first
energy beam. In some embodiments, directing the energy beam at the
target surface comprises directing the energy beam through a window
positioned within a recessed portion that supports the of the
enclosure. In some embodiments, the method further comprises
directing a purging flow of gas to a volume of the recessed
portion. In some embodiments, the purging flow of gas is in a
direction away from a surface of the window. In some embodiments,
the purging flow of gas is in a direction substantially parallel to
a surface of the window. In some embodiments, the method further
comprises directing the flow of gas out of the enclosure and
through a gas recycling system. In some embodiments, the gas
recycling system comprises: (a) a filtration system that filters
debris from the flow of gas exiting the enclosure, or (b) at least
one pump configured to increase a pressure of the flow of gas. In
some embodiments, the method further comprises supplying clean gas
to an outlet opening of a window housing. In some embodiments, the
window housing is coupled to the window. In some embodiments, the
inlet portion is configured to direct the flow of gas toward the
target surface. In some embodiments, the method further comprises
backflowing a portion of the flow of gas from the enclosure through
a back-flow outlet port that is proximal to an outlet port of a gas
inlet portion. In some embodiments, the flow of gas in the
enclosure facilitates a reduced amount of debris from interfering
with the printing of the 3D object. In some embodiments, the
reduced amount of debris corresponds to an amount that is not
material to formation of the 3D object. In some embodiments, a path
of the energy beam in a volume of a processing chamber of the
enclosure defines a processing cone, wherein the reduced amount of
debris is at least in the processing cone. In some embodiments, the
reduced amount of debris is adjacent to the target surface. In some
embodiments, the reduced amount of debris does not adhere to a
window through which the energy beam travels into a processing
chamber of the enclosure.
[0036] In another aspect, a system for printing a 3D object
comprises: an energy source configured to generate an energy beam
for transforming a pre-transformed material to a transformed
material; a platform configured to support the 3D object; and an
enclosure configured to enclose the platform, the enclosure
comprising: a window configured to allow the energy beam to pass
therethrough, and (i) a recessed portion that supports the window
and that includes a wall that defines a volume, (ii) an outlet
opening configured to direct a flow of gas into the volume in a
direction away from the window, or (iii) a combination of (i) and
(ii).
[0037] In some embodiments, the window has an internal window
surface that is exposed to the volume. In some embodiments, the
direction away from the window is at an acute angle with respect to
the internal window surface. In some embodiments, the window has a
plurality of outlet openings. In some embodiments, at least two of
the outlet openings face each other. In some embodiments, at least
a first opening and a second opening of the plurality of outlet
openings are configured such that: (a) the first opening directs a
first gas flow away from the window and towards the second opening,
and (b) the second opening directs a second gas flow away from the
window and towards the first opening. In some embodiments, the
second gas flow merges with the first gas flow to form a third gas
flow. In some embodiments, the first opening and the second opening
are configured to facilitate flowing the third gas flow towards a
plane of a target surface that is disposed in the enclosure. In
some embodiments, the window has an internal window surface that is
exposed to the volume. In some embodiments, a flow vector of the
flow of gas is non-tangential to the internal window surface. In
some embodiments, the flow of gas is characterized as having
cone-shaped convergence vectors. In some embodiments, the enclosure
includes a window housing that supports the window and at least
partially defines the recessed portion. In some embodiments, the
window housing includes a plenum portion that is configured to
supply gas to the outlet opening. In some embodiments, the outlet
opening is within the wall. In some embodiments, the system
comprises a plurality of windows that are configured to allow the
energy beam to pass therethrough. In some embodiments, the system
comprises a plurality of window housings that are configured to
support the plurality of windows. In some embodiments, the volume
is between the window and the platform. In some embodiments, the
recessed portion and/or an outlet opening within the wall is/are
configured to reduce an amount of debris from (i) altering the
energy beam, (ii) obstructing the window, or (iii) any combination
thereof. In some embodiments, altering the energy beam comprises
altering a wavelength, power density, or trajectory thereof. In
some embodiments, obstructing the window comprises adhering to
and/or reacting with the optical window.
[0038] In another aspect, a method for printing a 3D object
comprises: (a) directing an energy beam toward a platform to
transform at least a portion of a pre-transformed material to a
transformed material, wherein the platform is disposed in an
enclosure, wherein the energy beam is directed through a window
that is (i) positioned within a recessed portion of the enclosure,
the recessed portion including a wall that defines a volume, (ii)
proximate to an outlet opening configured to allow a flow of gas to
flow therethrough, or (iii) a combination of (i) and (ii); and (b)
in case of (ii) or (iii), directing the flow of gas through the
outlet opening in a direction away from the window.
[0039] In some embodiments, one or more controllers are
collectively or separately programed to direct operations (a) and
(b). In some embodiments, during operation (b), an insubstantial
amount of debris affects the printing of the 3D object. In some
embodiments, insubstantial comprises negligent, non-material,
inconsequential, trivial, or negligible. In some embodiments,
insubstantial is to a detectable degree. In some embodiments,
during operation (b) an insubstantial amount of debris interacts
with the energy beam. In some embodiments, during operation (b) an
insubstantial amount of debris accumulates on and/or obstructs the
window. In some embodiments, directing the flow of gas through the
outlet opening in the direction away from the window further
comprises directing the flow of gas into the volume of the recessed
portion. In some embodiments, the window has an internal window
surface that is exposed to the volume. In some embodiments, the
direction away from the window is at an acute angle with respect to
the internal window surface. In some embodiments, the window has an
internal window surface that is exposed to the volume. In some
embodiments, directing the flow of gas in operation (b) comprises
directing a flow vector of the flow of gas in a direction
non-tangential to the internal window surface. In some embodiments,
directing the flow of gas in operation (b) comprises directing the
flow of gas in convergence vectors. In some embodiments, the
convergence vectors have a triangular shape. In some embodiments,
the enclosure includes a window housing that supports the window
and at least partially defines the recessed portion. In some
embodiments, the window housing includes a plenum portion that
supplies gas to the outlet opening. In some embodiments, the method
further comprises flowing the gas through the plenum portion. In
some embodiments, the energy beam is a first energy beam and the
window is a first window. In some embodiments, the method further
comprising directing a second energy beam toward the platform
through a second window. In some embodiments, the second window is
positioned in a second recessed portion of the enclosure. In some
embodiments, the volume is between the window and the platform.
[0040] In another aspect, a system for printing a three-dimensional
(3D) object, the system comprises: a platform configured to support
the 3D object; and an enclosure configured to enclose at least the
platform during a printing operation, the enclosure operatively
coupled to, or comprises: a gas inlet portion at a first enclosure
side, the gas inlet portion configured to direct a flow of gas in a
first direction over a target surface that is (i) adjacent to the
platform, or (ii) comprises a surface of the platform, and a gas
outlet portion at a second enclosure side, the gas outlet portion
configured to direct the flow of gas out of the enclosure via at
least one outlet opening, wherein (a) the gas inlet portion
includes at least one baffle configured to direct gas in a second
direction different from the first direction, which gas is directed
within the gas inlet portion, (b) the gas outlet portion has a
cross-sectional shape that tapers toward the at least one outlet
opening, or (c) any combination of (a) and (b).
[0041] In some embodiments, the at least one baffle comprises at
least one surface that is substantially non-parallel (e.g., is
perpendicular) to the surface of the platform. In some embodiments,
the gas inlet portion opposes the gas outlet portion in space. In
some embodiments, the gas inlet portion further comprises at least
one flow aligner having walls that direct the flow of gas in the
first direction. In some embodiments, the at least one flow aligner
is more proximate to the platform than the at least one baffle. In
some embodiments, the at least one flow aligner directs gas within
the gas inlet portion toward an outlet port of the gas inlet
portion. In some embodiments, 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. In some embodiments, the gas
outlet portion comprises a first side (e.g., top) and an opposing
second side (e.g., bottom). In some embodiments, the first side
tapers toward the at least one outlet opening more than the second
side tapers toward the at least one outlet opening. In some
embodiments, the second side is more proximate to the platform than
the first side. In some embodiments, the first direction is
substantially parallel to the target surface. In some embodiments,
the gas inlet portion is configured to alter a shape, a volume, a
velocity, a direction, or an alignment of the flow of gas. In some
embodiments, the platform is configured to vertically translate. In
some embodiments, the platform is configured to translate in a
direction that is substantially non-parallel (e.g., is
perpendicular) to the first direction. In some embodiments, the
system further comprises an energy source configured to generate an
energy beam for transforming at least a portion of a
pre-transformed material to a transformed material as part of the
3D object. In some embodiments, the gas inlet portion and/or the
outlet portion comprises at least one filter configured to reduce
an amount of gas-borne material within the enclosure. In some
embodiments, the at least one filter comprises a High-Efficiency
Particulate Arrestance (HEPA) filter. In some embodiments, the gas
outlet portion is separated by a main portion of the enclosure by a
wall. In some embodiments, the wall comprises one or more openings
configured to allow the flow of gas to enter the gas outlet portion
from the main portion of the enclosure. In some embodiments, a size
of the one or more openings is adjustable. In some embodiments, the
gas inlet portion comprises a flow aligning structure (e.g.,
comprises the at least flow aligner) configured to align the flow
of gas in the first direction by directing the flow of gas through
a plurality of channels. In some embodiments, the flow aligning
structure is positioned at a part of the gas inlet portion adjacent
the platform. In some embodiments, the flow aligning structure is
positioned at a bottom part of the gas inlet portion. In some
embodiments, the flow aligning structure has a height of at most
about 5, 4, 3, 2, 1, or 0.5 inches. In some embodiments, the
enclosure is configured to hold a positive pressure. In some
embodiments, the at least one baffle comprises a surface that is
configured to (i) minimize friction between the flow of gas and the
surface of the baffle and/or (ii) reduce a reactive species in the
flow of gas. In some embodiments, the surface is polished. In some
embodiments, the surface comprises an absorbing species of the
reactive species, or a quenching agent to the reactive species. In
some embodiments, the absorbing species is a chelate. In some
embodiments, the absorbing species is a desiccant. In some
embodiments, the gas inlet portion is configured to facilitate (I)
expansion of a cross section of the flow of gas as it flows through
the gas inlet portion and/or (II) homogenization of the flow of gas
through the cross section. In some embodiments, the at least one
baffle is configured to facilitate (I) expansion of a cross section
of the flow of gas as it flows through the gas inlet portion and/or
(II) homogenization of the flow of gas through the cross section.
In some embodiments, the cross section is a vertical cross section.
In some embodiments, the vertical cross section is expanded to
encompass a fundamental length scale (e.g., width) of the platform.
In some embodiments, the cross-sectional shape that tapers is
configured to reduce turbulence, backflow, and/or standing vortices
in a processing cone volume by tapering the flow of gas. In some
embodiments, the processing cone is above the target surface or
comprises the target surface. In some embodiments, the at least one
baffle is configured to be exchangeable and/or movable. In some
embodiments, the exchangeable and/or movable is before, during
and/or after the printing.
[0042] In another aspect, a method for printing a 3D object, the
method comprises: (a) directing a flow of gas through an enclosure
from a gas inlet portion to a gas outlet portion, which flow of gas
is in a first direction over a target surface that is (i) adjacent
to a platform configured to support the 3D object, or (ii)
comprises a surface of the platform; and (b) using at least one
baffle of the gas inlet portion to direct the flow of gas in a
second direction different from the first direction as it flows
through the gas inlet portion, (b) tapering the flow of gas within
the gas outlet portion toward at least one outlet opening of the
gas outlet portion, or (c) a combination of (a) and (b).
[0043] In some embodiments, the second direction is substantially
non-parallel to the first direction. In some embodiments, the
second direction is substantially orthogonal to the first
direction. In some embodiments, the first direction is
substantially parallel to the surface of the platform. In some
embodiments, the method further comprises aligning the flow of gas
in the first direction by directing the flow of gas through a
plurality of channels within the gas inlet portion. In some
embodiments, the method further comprises directing an energy beam
toward the platform to transform a pre-transformed material to a
transformed material as part of the printing of the 3D object. In
some embodiments, the method further comprises causing the flow of
gas to flow through at least one filter (e.g., HEPA filter) prior
to entering the gas inlet portion. In some embodiments, the method
further comprises translating the platform. In some embodiments,
translating the platform comprises vertically translating the
platform. In some embodiments, translating the platform comprises
translating the platform in a third direction different than the
first direction. In some embodiments, the third direction is
substantially non-parallel to the first direction. In some
embodiments, the third direction is substantially orthogonal to the
first direction. In some embodiments, the method further comprises
expanding a cross section of the flow of gas during its flow
through the gas inlet portion. In some embodiments, the cross
section is a vertical cross section. In some embodiments, the
vertical cross section is expanded to encompass a fundamental
length scale (e.g., width) of the platform. In some embodiments,
the method further comprises using the at least one baffle for the
expanding. In some embodiments, the method further comprises
homogenizing the flow of gas across a cross section of the flow of
gas during its flow through the gas inlet portion. In some
embodiments, the cross section is a vertical cross section. In some
embodiments, the vertical cross section is homogenized along a
fundamental length scale (e.g., width) of the platform. In some
embodiments, the method further comprises using the at least one
baffle for the homogenizing. In some embodiments, the method
further comprises reducing turbulence, backflow, and/or standing
vortices in a processing cone volume by tapering the flow of gas.
In some embodiments, the processing cone is above the target
surface or comprises the target surface. In some embodiments, the
method further comprises exchanging the at least one baffle. In
some embodiments, the exchanging is before, during and/or after the
printing. In some embodiments, the method further comprises moving
the at least one baffle. In some embodiments, the exchanging is
before, during and/or after the printing.
[0044] In another aspect, an apparatus for printing a 3D object,
the apparatus comprises: a platform configured to support the 3D
object during the printing; an energy source configured to generate
an energy beam that transforms a pre-transformed material to a
transformed material to print the 3D object, which energy beam is
operatively coupled to the platform; a window that facilitates
transmittal of the energy beam therethrough; and a wall configured
to at least in part support the window and define a volume adjacent
to the window, which wall comprises (i) a channel configured to
facilitate flow of a gas therethrough, and (ii) an opening of the
channel configured to direct flow of the gas away from the window,
which opening is disposed adjacent to the window.
[0045] In some embodiments, the window is an optical window. In
some embodiments, the platform is housed in an enclosure that
comprises an outlet opening configured to direct a flow of gas into
the volume in the direction away from the window. In some
embodiments, the platform is housed in an enclosure that comprises
the volume, the wall, and the window. In some embodiments, the
window comprises an internal window surface that is exposed to the
volume. In some embodiments, the direction away from the window is
at an acute angle with respect to the internal window surface. In
some embodiments, the wall comprises a plurality of (outlet)
openings. In some embodiments, at least two of the (outlet)
openings face each other. In some embodiments, the opening
corresponds to an annular-shaped slit. In some embodiments, the
wall comprises the (outlet) opening that is configured to direct
the gas flow away from the window. In some embodiments, away from
the window comprises towards the platform, downwards, in a vertical
direction, and/or towards a gravitational center (e.g., of earth).
In some embodiments, the flow of the gas that is directed flows in
a laminar or spiral flow in a direction away from the window. In
some embodiments, the wall has a plurality of outlet openings. In
some embodiments, at least a first opening and a second opening of
the plurality of outlet openings are configured such that: the
first opening directs a first gas flow (i) away from the window
and/or (ii) towards the second opening, and the second opening
directs a second gas flow away from the window and/or towards the
first opening. In some embodiments, the second gas flow merges with
the first gas flow to form a third gas flow, and wherein the first
opening and the second opening are configured to facilitate flowing
the third gas flow towards the platform, towards a gravitational
center, downwards, and/or in a vertical direction. In some
embodiments, the window has an internal window surface that is
exposed to the volume. In some embodiments, a flow vector of the
flow of the gas is non-tangential to the internal window surface.
In some embodiments, the outlet is configured to facilitate a flow
of gas away from the window that is characterized as having
cone-shaped convergence vectors. In some embodiments, the apparatus
further comprises a holder configured to support the window. In
some embodiments, the holder is operatively coupled to the wall and
to the window. In some embodiments, the apparatus is configured to
facilitate reduction in an amount of a debris formed during the
printing from (i) altering the energy beam, (ii) obstructing the
window, or (iii) a combination of (i) and (ii). In some
embodiments, altering the energy beam comprises altering a
wavelength, power density, or trajectory thereof. In some
embodiments, obstructing the window comprises adhering to and/or
reacting with the window. In some embodiments, the window comprises
a material having a thermally conductivity higher than that of
fused silica. In some embodiments, the material is substantially
transparent to at least a portion of wavelengths of the energy
beam. In some embodiments, the window comprises sapphire, crystal
quartz, zinc selenide (ZnSe), magnesium fluoride (MgF.sub.2), or
calcium fluoride (CaF.sub.2). In some embodiments, the window
comprises a material having a thermal conductivity of at least
about 5 W/m.degree. C. at 300 K. In some embodiments, the enclosure
is configured to maintain an internal atmosphere at a positive
pressure. In some embodiments, the energy source is configured to
direct the energy beam through another volume defined by a
processing cone within the enclosure. In some embodiments, the
enclosure comprises at least one vacuum duct that is configured to
remove at least a portion of debris within the processing cone. In
some embodiments, the channel comprises a portion that is different
from a horizontal channel. In some embodiments, the channel
comprises a vertical channel portion. In some embodiments, the
channel is a covered channel. In some embodiments, the opening
forms an acute angle with the (e.g., optical) window. In some
embodiments, the acute angle points the opening towards the
platform. In some embodiments, the flow of the gas is filtered by a
HEPA filter prior to its entry into the channel.
[0046] In another aspect, a method for printing a 3D object, the
method comprises: (a) directing an energy beam through a window
toward a platform to transform at least a portion of a
pre-transformed material to a transformed material to form the 3D
object; and (b) directing a flow of a gas in a direction away from
the window, which gas flows through a channel in a wall and through
an outlet opening in the wall, which wall at least in part supports
the window, which outlet opening is adjacent to the window, which
outlet opening is coupled to the channel.
[0047] In some embodiments, one or more controllers collectively or
separately are programed to direct the operations of (a) and (b).
In some embodiments, during operation (b), a reduced amount of
debris affects the printing of the 3D object. In some embodiments,
reduced is in comparison to lack of the flow of the gas. In some
embodiments, during operation (b), an insubstantial amount of
debris affects the printing of the 3D object. In some embodiments,
insubstantial comprises negligent, non-material, inconsequential,
trivial, or negligible. In some embodiments, insubstantial is to a
detectable degree. In some embodiments, during operation (b) an
insubstantial amount of debris interacts with the energy beam. In
some embodiments, during operation (b) an insubstantial amount of
debris accumulates on and/or obstructs the window. In some
embodiments, during operation (b), a substantially undetectable
amount of debris affects a peak intensity of the energy beam used
to transform the pre-transformed material. In some embodiments,
during operation (b), a peak intensity of the energy beam is
substantially unchanged after transformation of at least 500 layers
of pre-transformed material. In some embodiments, during operation
(b), a peak intensity of the energy beam is substantially unchanged
after transformation of at least about 3.4 milliliters of
pre-transformed material. In some embodiments, directing the flow
of the gas through the outlet opening in the direction away from
the window further comprises directing the flow of the gas into a
volume of a recessed portion defined at least in part by the wall
and the window. In some embodiments, the window has an internal
window surface that is exposed to the volume. In some embodiments,
a direction away from the window is at an acute angle with respect
to the internal window surface. In some embodiments, the window has
an internal window surface that is exposed to the volume. In some
embodiments, directing the flow of the gas in operation (b)
comprises directing a flow vector of the flow of gas in a direction
non-tangential to the internal window surface. In some embodiments,
directing the flow of the gas in operation (b) comprises directing
the flow of gas in convergence vectors. In some embodiments, the
convergence vectors have a triangular shape. In some embodiments,
the flow of the gas flows away from the window comprises a
pyramidal, conical, and/or spiraling shape in a recessed portion
defined at least in part by the wall and the window. In some
embodiments, the platform is disposed in an enclosure that includes
a window housing that supports the window and at least partially
defines the recessed portion. In some embodiments, the window
housing includes a plenum portion that supplies gas to the outlet
opening, and wherein the method further comprises flowing the gas
through the plenum portion. In some embodiments, the window housing
comprises the wall. In some embodiments, the energy beam is a first
energy beam and the window is a first window, the method further
comprises directing a second energy beam toward the platform
through a second window. In some embodiments, the platform is
disposed in an enclosure that includes the window that is part of a
first recessed portion. In some embodiments, the second window is
positioned in a second recessed portion of the enclosure. In some
embodiments, the volume is between the window and the platform.
[0048] In another aspect, a system for printing a 3D object, the
system comprises: a platform configured to support the 3D object
(e.g., during the printing); a material dispenser configured to
dispense a pre-transformed material towards the platform, wherein
the material dispenser is configured to traverse in a first
direction adjacent to the platform; and a gas flow director
configured to direct a flow of gas in a second direction adjacent
the platform, wherein the first direction is non-parallel to the
second direction.
[0049] In some embodiments, the platform is configured to support a
material bed that comprises the pre-transformed material. In some
embodiments, the material dispenser is part of a layer forming
apparatus is configured to dispense a planar layer of
pre-transformed material above the platform. In some embodiments,
adjacent to the platform comprises above the platform and/or
parallel to the platform. In some embodiments, the first direction
is substantially orthogonal to the second direction. In some
embodiments, the system further comprises an enclosure configured
to enclose the platform. In some embodiments, the enclosure
comprises a processing chamber that is configured to enclose the at
least one layer of pre-transformed material during a transformation
process. In some embodiments, the enclosure is configured to house
the material dispenser. In some embodiments, the material dispenser
is housed in an ancillary chamber during a transformation process.
In some embodiments, the ancillary chamber is comprised in the
enclosure. In some embodiments, the gas flow director comprises (i)
a gas inlet portion at a first side of the enclosure, (ii) a gas
outlet portion at a second side of the enclosure, or (iii) a
combination of (i) and (ii). In some embodiments, the enclosure is
operatively coupled to, or comprises, the gas inlet portion. In
some embodiments, the enclosure is operatively coupled to, or
comprises, the gas outlet portion. In some embodiments, the gas
flow director is configured to control one or more of a shape, a
velocity, a temperature, a chemical makeup, and a uniformity, of
the flow of gas. In some embodiments, the gas flow director is
configured to impart a (e.g., substantially) planar shape to the
flow of gas at least above the platform. In some embodiments, the
gas flow director comprises a gas inlet portion comprises an
elongated aperture that imparts a (e.g., substantially) planar
shape to the flow of gas at least above the platform. In some
embodiments, the gas flow director comprises a gas inlet portion
comprises at least one baffle configured to change a direction of
the flow of gas, uniformity along a (e.g., vertical) cross section
of the flow of gas, and/or a size of a (e.g., vertical) cross
section of the flow of gas, in the gas inlet portion. In some
embodiments, change comprises adjust temperature, adjust chemical
makeup (e.g., level of a reactive agent, e.g., oxygen or humidity),
homogenize or expand, the flow of gas. In some embodiments, the at
least one baffle is configured to change a direction of the flow of
gas within the gas flow director to a third direction different
than (a) the first direction, (b) the second direction, or (c) the
first and second directions. In some embodiments, the gas flow
director comprises a gas inlet portion comprises at least one
alignment structure configured to align portions of the flow of gas
in the gas inlet portion (e.g., in accordance with the second
direction). In some embodiments, the at least one alignment
structure includes walls that align the portions of the flow of gas
within the gas inlet portion. In some embodiments, the gas flow
director comprises at least one valve configured to control a
velocity and/or pressure of the flow of gas. In some embodiments,
the system further comprises an enclosure configured to enclose at
least one layer of pre-transformed material during a printing
operation. In some embodiments, the system further comprises an
energy source configured to generate an energy beam for
transforming at least a portion of the at least one layer to a
transformed material. In some embodiments, the system further
comprises an enclosure. In some embodiments, the energy source is
configured to direct the energy beam defined by a processing cone
within the enclosure. In some embodiments, the enclosure comprises
at least one vacuum duct that is configured to remove at least a
portion of debris within and/or out of the processing cone. In some
embodiments, the material dispenser is configured to translate
(e.g., laterally) over the platform. In some embodiments, the gas
flow director is configured to direct the flow of gas over the
platform. In some embodiments, the platform is configured to
support multiple layers of pre-transformed material as a material
bed. In some embodiments, the system further comprises at least one
controller configured to cause the material dispenser to dispense
the pre-transformed material (e.g., while the gas flow director
directs the flow of gas in the second direction). In some
embodiments, the material dispenser is part of a layer forming
apparatus that further comprises a leveler, or a material remover.
In some embodiments, the layer forming apparatus is configured to
form a (e.g., substantially) planar shaped at least one layer of
pre-transformed material. In some embodiments, the material
dispenser having an opening that is configured to dispense a
pre-transformed material therethrough. In some embodiments, the
layer forming apparatus comprises a leveler having an elongated
edge that is configured to level an exposed surface of a material
bed. In some embodiments, the layer forming apparatus comprises a
material remover having an elongated opening that is configured to
accept at least a portion of material from a material bed
therethrough. In some embodiments, the system further comprises at
least one controller configured to cause the layer forming
apparatus to form the at least one layer of pre-transformed
material (e.g., while the gas flow director directs the flow of gas
in the second direction). In some embodiments, the system further
comprises at least one controller configured to cause the layer
forming apparatus to form the at least one layer of pre-transformed
material (e.g., while the gas flow director is directing the flow
of gas in the second direction). In some embodiments, the system
further comprises at least one controller configured to cause the
gas flow director to direct the flow of gas out of the enclosure
(e.g., and away from the platform), e.g., while the layer forming
apparatus forms the at least one layer of pre-transformed material.
In some embodiments, the system further comprises at least one
controller configured to cause the flow of gas director to direct
the flow of gas out of an enclosure while the material dispenser
dispenses the pre-transformed material. In some embodiments, the
enclosure comprises: the platform, at least part of the flow of
gas, and the material dispenser In some embodiments, away from the
platform comprises outside of an enclosure configured to enclose
the at least one layer of pre-transformed material during a
printing operation. In some embodiments, the gas flow director
comprises a gas inlet portion and/or a gas outlet portion. In some
embodiments, the gas inlet portion and/or the gas outlet portion
comprises at least one filter configured to control a quality of
the flow of gas. In some embodiments, the at least one filter
comprises a HEPA filter. In some embodiments, the gas flow director
is configured to control at least one characteristic of the flow of
gas. In some embodiments, the system further comprises at least one
controller operatively coupled to the gas flow director. In some
embodiments, the at least one controller is configured to
effectuate the control. In some embodiments, the at least one
characteristic of the flow of gas comprises: velocity, fundamental
cross section of a volume of the flow of gas, homogeneity of a
volume of the flow of gas in a cross section, chemical makeup of
the flow of gas, laminarity of the flow of gas, turbulence of the
flow of gas, or a temperature of the flow of gas. In some
embodiments, the cross section is a vertical cross section. In some
embodiments, the vertical cross section encompasses a fundamental
length scale of the platform.
[0050] In another aspect, a method of printing a 3D object, the
method comprises: (a) using a material dispenser to dispense
pre-transformed material towards a platform while traversing the
material dispenser in a first direction adjacent to the platform;
and (b) using a gas flow director to direct a flow of gas in a
second direction adjacent to the platform. In some embodiments, the
first direction is non-parallel to the second direction.
[0051] In some embodiments, the material dispenser is part of a
layer forming apparatus used to form a planar layer of
pre-transformed material disposed above the platform. In some
embodiments, the method further comprises transforming at least a
portion of the pre-transformed material to a transformed material
to print the 3D object. In some embodiments, the method further
comprises using an energy beam to effectuate the transforming. In
some embodiments, using the gas flow director to direct a flow of
gas in a second direction is during the printing. In some
embodiments, using the material dispenser is during a period
different from when transforming the pre-transformed material to a
transformed material as part of the 3D object. In some embodiments,
using the gas flow director to direct a flow of gas in a second
direction is when transforming the pre-transformed material to a
transformed material as part of the 3D object. In some embodiments,
the method further comprises controlling one or more
characteristics of the flow of gas. In some embodiments, one or
more characteristics of the flow of gas differs (i) when
transforming the pre-transformed material to a transformed material
as part of the 3D object as compared to a period lacking the
transforming, and/or (ii) while using the material dispenser as
compared to during a period where the material dispenser is not
used to dispense the pre-transformed material. In some embodiments,
the flow of gas is flowing at a different rate (i) when
transforming the pre-transformed material to a transformed material
as part of the 3D object as compared to a period lacking the
transforming and/or (i) while using the material dispenser as
compared to during a period where the material dispenser is not
used to dispense the pre-transformed material. In some embodiments,
using the flow of gas comprises controlling one or more
characteristics of the flow of gas. In some embodiments, using the
flow of gas comprises altering one or more characteristics of the
flow of gas. In some embodiments, the first direction is
substantially orthogonal to the second direction. In some
embodiments, the method further comprises directing the flow of gas
through a gas inlet portion prior to directing the flow of gas
adjacent to the platform. In some embodiments, the method further
comprises modifying at least one of a shape, a velocity, a chemical
makeup (e.g., level of a reactive agent), a temperature, or a
uniformity of the flow of by flowing the flow of gas through a gas
inlet portion that is coupled to or is a part of an enclosure that
comprises the platform, at least part of the flow of gas, and the
material dispenser. In some embodiments, the reactive agent reacts
with a by-product of the printing and/or the pre-transformed
material under the printing, flow of gas, and/or gas filtration
conditions. In some embodiments, the method further comprises
directing the flow of gas through a gas outlet portion subsequent
to directing the flow of gas adjacent to the platform. In some
embodiments, the method further comprises directing an energy beam
toward the platform to transform at least a portion of the at least
one layer of pre-transformed material to a transformed material. In
some embodiments, the method further comprises translating the
platform. In some embodiments, the platform is translated in a
third direction that is different than at least one of the first
and second directions. In some embodiments, the third direction is
substantially orthogonal to at least one of the first and second
directions.
[0052] In another aspect, a system for printing a 3D object, the
system comprises: a platform configured to support at least one
layer of pre-transformed material; a layer forming apparatus
configured to traverse adjacent the platform and dispense a
pre-transformed material towards the platform; and a gas flow
director configured to direct a flow of gas at a velocity adjacent
the platform, wherein the gas flow director is configured to alter
the velocity for at least a portion time that the layer forming
apparatus traverses adjacent the platform.
[0053] In some embodiments, the layer forming apparatus is
configured to dispense a planar layer of the pre-transformed
material. In some embodiments, the pre-transformed material forms a
material bed, and wherein the platform is configured to support the
material bed. In some embodiments, the system further comprises an
energy source configured to generate an energy beam that transforms
the pre-transformed material to a transformed material as part of
the 3D object. In some embodiments, alter the velocity comprises
increase or decrease the velocity. In some embodiments, alter
comprises linear alteration of the velocity. In some embodiments,
the gas flow director is configured to change the flow of gas when
the layer forming apparatus is dispensing the pre-transformed
material. In some embodiments, the gas flow director is configured
to change the flow of gas when the layer forming apparatus is
dispensing the pre-transformed material. In some embodiments, the
layer forming apparatus comprises at least one of (i) a material
dispenser configured to dispense the at least one layer of
pre-transformed material, (ii) a material remover configured to
remove at least a portion of the at least one layer of
pre-transformed material, or (iii) leveler configured to level an
exposed surface of the at least one layer of pre-transformed
material. In some embodiments, the material dispenser and the
material remover traverse together over the platform. In some
embodiments, the material dispenser is configured to dispense the
at least one layer of pre-transformed material when traversing in a
forward direction over the platform. In some embodiments, and the
material remover is configured to remove the at least a portion of
the at least one layer of pre-transformed material when traversing
in a reverse direction over the platform. In some embodiments, the
gas flow director comprises at least one valve. In some
embodiments, the at least one valve (a) constricts the flow of gas,
(b) obstructs the flow of gas, (c) diverts the flow of gas, or (d)
at least two of (a), (b) or (c). In some embodiments, the gas flow
director is configured to divert at least a portion of the flow of
gas to a gas outlet. In some embodiments, the gas flow director is
configured to divert at least a portion of the flow of gas to a
recycling system. In some embodiments, the gas flow director
comprises a flow diverter configured to divert the flow of gas
within an enclosure that encloses the pre-transformed material
during printing. In some embodiments, the system further comprises
at least one pump configured to supply the flow of gas. In some
embodiments, the system further comprises at least one upstream
valve and/or at least one downstream valve that is/are configured
to at least partially control altering the velocity. In some
embodiments, the system further comprises at least one filter
configured to control a quality of the flow of gas. In some
embodiments, the at least one filter comprises a HEPA filter. In
some embodiments, the platform is configured to traverse in a
vertical direction. In some embodiments, the platform is configured
to traverse during printing. In some embodiments, the platform is
configured to traverse in a direction that is non-parallel to a
direction of the flow of gas.
[0054] In another aspect, a method of printing a 3D object, the
method comprises: (A) traversing a layer forming apparatus adjacent
a platform to dispense a pre-transformed material towards the
platform; and (B) causing a gas flow director to direct a flow of
gas adjacent the platform, wherein the gas flow director directs
the flow of gas at a first velocity for at least a portion time
that the layer forming apparatus is traversing adjacent the
platform and at a second velocity for at least a portion of time
that the layer forming apparatus is not traversing adjacent the
platform.
[0055] In some embodiments, the first velocity is greater than the
second velocity. In some embodiments, the first velocity is less
than the second velocity. In some embodiments, the gas flow
director changes the flow of gas between the first velocity and the
second velocity by diverting at least a portion of the flow of gas
to a region within an enclosure that encloses the pre-transformed
material. In some embodiments, the diverting is during the
printing. In some embodiments, diverting the at least the portion
of the flow of gas is toward a gas outlet. In some embodiments, the
gas flow director changes the flow of gas between the first
velocity and the second velocity by adjusting at least one pump
that at least partially supplies and/or pressurizes the flow of
gas. In some embodiments, the gas flow director changes the flow of
gas between the first velocity and the second velocity by using at
least one valve to (a) constrict the flow of gas, (b) obstruct the
flow of gas, (c) divert the flow of gas, or (d) at least two of
(a), (b) or (c). In some embodiments, the gas flow director changes
the flow of gas between the first velocity and the second velocity
during the printing. In some embodiments, the method further
comprises directing an energy beam toward the platform to transform
the pre-transformed material to a transformed material to print the
3D object. In some embodiments, the gas flow director changes the
flow of gas between the first velocity and the second velocity
during transformation of the pre-transformed material to a
transformed material. In some embodiments, the method further
comprises translating the platform. In some embodiments, the method
further comprises translating the platform during the printing.
[0056] In another aspect, a system for printing a 3D object, the
system comprises: a platform configured to support the 3D object
during the printing; an enclosure configured to enclose the 3D
object within an internal atmosphere comprises a gas (e.g., during
printing); and a filtering system configured to filter a gas-borne
material from a flow of the gas that exits the enclosure, the
filtering system comprises: a first canister operationally coupled
with the enclosure and comprises a first filter, a second canister
operationally coupled with the enclosure and comprises a second
filter, wherein each of the first and second filters is configured
to separate the gas-borne material from the flow of the gas, and at
least one valve configured to switch a direction of the flow of the
gas between the first canister and the second canister, which
switching facilitates uninterrupted separation of the gas-borne
material from the flow of the gas during the printing.
[0057] In some embodiments, during the printing, each of the first
and second filters is configured to (i) separate the gas-borne
material from the flow of the gas. In some embodiments, each of the
first and second filters is further configured to (i) separate the
gas-borne material from an external atmosphere, and/or (ii)
separate the flow of the gas from the external atmosphere. In some
embodiments, during the printing, each of the first and second
filters is further configured to (i) separate the gas-borne
material from an external atmosphere, and/or (ii) separate the flow
of the gas from the external atmosphere. In some embodiments, the
system further comprises at least one pump configured to supply a
pumping force that drives the flow of the gas through at least one
of the first canister or the second canister and back into the
enclosure. In some embodiments, the at least one pump is configured
to direct the flow of the gas from an outlet port of the enclosure
to an inlet port of the enclosure. In some embodiments, the first
and second canisters are configured to substantially prevent a
reactive agent in an external atmosphere from reacting with the
gas-borne material within the first and second canisters
respectively. In some embodiments, the first canister is fluidly
coupled with the second canister. In some embodiments, fluidly
coupled comprises facilitating travel of the gas and/or the gas
borne material. In some embodiments, the first canister is fluidly
coupled with the enclosure. In some embodiments, the second
canister is fluidly coupled with the enclosure. In some
embodiments, the platform is configured to traverse during
printing. In some embodiments, the platform is configured to
vertically traverse. In some embodiments, the enclosure is
configured to maintain the internal atmosphere at a positive
pressure. In some embodiments, the system further comprises a third
filter coupled with a wall of the enclosure. In some embodiments,
the third filter is within or proximate to a gas inlet portion
and/or a gas outlet portion of the enclosure. In some embodiments,
the first filter and/or the second filter comprises a HEPA filter.
In some embodiments, the first canister comprises a first casing
material and the second canister comprises a second casing
material. In some embodiments, the first casing material has a
different (i) material type, (ii) casing wall structure, (iii)
casing shape, or (iv) at least two of (i) to (iii) compared to the
second casing material. In some embodiments, the first canister
comprises a first casing material and the second canister comprises
a second casing material. In some embodiments, the first casing
material has the same (i) material type, (ii) casing wall
structure, (iii) casing shape, or (iv) at least two of (i) to (iii)
as the second casing material. In some embodiments, the first
canister comprises a first casing material and the second canister
comprises a second casing material. In some embodiments, at least
one of the first and/or the second casing materials includes one or
more layers. In some embodiments, the one or more layers comprise a
solid layer, a liquid layer, a semi-solid layer, or a gas-layer. In
some embodiments, the first canister comprises a first valve. In
some embodiments, the first valve operatively couples the first
canister to the enclosure. In some embodiments, the second canister
comprises a second valve. In some embodiments, the second valve
operatively couples the second canister to the enclosure. In some
embodiments, the at least one valve is configured to reversibly
decouple the first canister and/or the second canister from the
enclosure. In some embodiments, the gas-borne material comprises at
least one of debris, soot, or pre-transformed material. In some
embodiments, the system further comprises at least one sensor
configured to detect (i) a reactive agent, or (ii) the gas-borne
material in the flow of gas. In some embodiments, the reactive
agent is reactive with the gas borne material under the conditions
prevailing in the enclosure, first canister, and/or second
canister. In some embodiments, the reactive agent comprises oxygen
or water. In some embodiments, the system further comprises at
least one sensor configured to detect (i) a presence or absence of
the first filter and/or the second filter, (ii) a reactive species
of the gas, (iii) a velocity of the gas traveling, or (iv) a
pressure, in the first canister and/or the second canister. In some
embodiments, detect is (i) during the printing, and/or (ii) a
filtration process in the first canister and/or the second
canister. In some embodiments, the at least one sensor is coupled
to at least one controller (e.g., respectively). In some
embodiments, the at least one controller is configured to (i)
control the flow of gas, (ii) direct replacement of the first
filter and/or the second filter, and/or (iii) direct decoupling of
the first canister and/or the second canister from the enclosure
(e.g., considering an output from the sensor).
[0058] In another aspect, a method of printing a 3D object, the
method comprises: (a) directing a flow of gas out of an enclosure
that is configured to enclose the 3D object within an internal
atmosphere during printing; and (b) uninterruptedly during the
printing, using a filtering system operationally coupled to the
enclosure to filter a gas-borne material from the flow of gas out
of the enclosure, wherein using the filtering system comprises: (i)
filtering the gas borne material in a first canister by passing the
flow of gas through a first filter disposed in the first canister,
(ii) directing the flow of gas from the first canister to a second
canister, and (iii) filtering the gas borne material in the second
canister by passing the flow of gas through a second filter
disposed in the second canister to form a filtered gas.
[0059] In some embodiments, the method further comprises
facilitating insertion of the filtered gas into the enclosure. In
some embodiments, the method further comprises maintaining the flow
of gas at or below (e.g., a pre-determined) velocity, temperature,
and/or pressure associated with a risk of a violent reaction
between the gas-borne material and a reactive agent (e.g., from an
external atmosphere). In some embodiments, the method further
comprises causing at least one pump to drive the flow of gas
through the first canister gas and/or second canister. In some
embodiments, the method further comprises printing the 3D object.
In some embodiments, the gas-borne material is generated during the
printing. In some embodiments, directing the flow of gas in the
enclosure comprises directing the flow of gas from a gas inlet
portion toward a gas outlet portion of the enclosure. In some
embodiments, directing the flow of gas is adjacent a material bed.
In some embodiments, the material bed is supported by a platform,
the method further comprises vertically translating the platform.
In some embodiments, the platform is vertically translated during
printing of the 3D object. In some embodiments, the method further
comprises printing the 3D object by directing an energy beam at a
material bed comprises a pre-transformed material to form a
transformed material as part of the 3D object. In some embodiments,
directing the gas flow from the first canister to a second canister
comprises using at least one valve to switch a direction of the
flow of gas from the first canister to the second canister. In some
embodiments, using the at least one valve comprises altering a
status of the at least one valve. In some embodiments, using the at
least one valve comprises operationally decoupling the first
canister or the second canister from the enclosure. In some
embodiments, directing the flow of gas from the first canister to a
second canister comprises altering a status of a first valve
associated with the first canister and altering a status of a
second valve associated with the second canister. In some
embodiments, the method further comprises detecting (i) a presence
or absence of the first filter and/or second filters, (ii) a
reactive species in the flow of gas, (iii) a velocity of the flow
of the gas, or (iv) a pressure, or (v) a temperature of the flow of
gas, in the first canister and/or second canister. In some
embodiments, detecting is (i) during the printing, and/or (ii) a
filtration process in the first canister and/or second canister. In
some embodiments, the method further comprises using at least one
controller to (i) control the flow of gas, (ii) direct replacement
of the first filter and/or second filter, and/or (iii) direct
decoupling of the first canister and/or second canister from the
enclosure (e.g., considering an output from the sensor).
[0060] In another aspect, a system for printing a 3D object, the
system comprises: an energy source configured to generate an energy
beam for transforming a pre-transformed material to a transformed
material; a platform configured to support the 3D object during the
printing; and an enclosure configured to enclose at least a portion
the platform, the enclosure comprises: a first wall; at least one
window configured to allow the energy beam to pass therethrough,
and a recessed portion relative to the first wall, which recessed
portion comprises the at least one window and a second wall that at
least partially separates the recessed portion from the first wall,
which at least one window and second wall define a volume of the
recessed portion.
[0061] In some embodiments, the at least one window is disposed at
a position to facilitate a path of the energy beam to travel
therethrough. In some embodiments, the path of the energy beam is
directed toward the platform. In some embodiments, the second wall
is configured to facilitate at least partial shielding of an
interior surface of the window from a gas-borne material in the
enclosure. In some embodiments, the at least partial shielding is
during the printing. In some embodiments, the gas-borne material is
produced during the printing. In some embodiments, the recessed
portion comprises a window holder portion that is configured to
support the at least one window. In some embodiments, the window
holder portion is comprised in a further recessed volume. In some
embodiments, the recessed portion comprises a plurality of window
holder portions. In some embodiments, the plurality of window
holder portions are (e.g., substantially) aligned with a direction
of a flow of gas above the platform. In some embodiments, the
system further comprises a plurality of window holder portions that
are configured to support the window. In some embodiments,
plurality of window holder portions are arranged in a (e.g.,
substantially) non-parallel alignment with a direction of a flow of
gas above the platform. In some embodiments, each of the plurality
of window holder portions supports a window. In some embodiments,
each of the plurality of window holder portions supports a
plurality of windows. In some embodiments, the window holder
portion comprises a purging system configured to direct a flow of
gas within the further recessed volume. In some embodiments, the
purging system is configured to direct the flow of gas away from
the window. In some embodiments, the purging system comprises one
or more channels. In some embodiments, the second wall comprises
the one or more channels. In some embodiments, the system further
comprises a plurality of windows that include the window. In some
embodiments, the plurality of windows are arranged in a
non-parallel alignment with a direction of a flow of gas above the
platform. In some embodiments, the second wall comprises sides that
at least partially enclose a volume of the recessed portion. In
some embodiments, the system comprises at plurality of recessed
portions. In some embodiments, the system comprises a plurality of
energy sources. In some embodiments, the volume is between the
window and the platform. In some embodiments, the window comprises
a material having a thermally conductivity higher than that of
fused silica. In some embodiments, the material is substantially
transparent to at least a portion of wavelengths of the energy
beam. In some embodiments, the window comprises at least one of
sapphire, crystal quartz, zinc selenide (ZnSe), magnesium fluoride
(MgF.sub.2), or calcium fluoride (CaF.sub.2). In some embodiments,
window comprises a material having a thermal conductivity
measurement of at least 5 (Watts per meter per degrees Celsius)
W/m.degree. C. at 300 Kelvin (K). In some embodiments, the energy
source is configured to direct the energy beam defined by a
processing cone within the enclosure. In some embodiments, the
enclosure comprises at least one vacuum duct that is configured to
remove at least a portion of debris within and/or outside of the
processing cone. In some embodiments, the recessed portion
comprises one or more sensors configured to detect one or more
input parameters within the enclosure during the printing. In some
embodiments, the system further comprises at least one sensor
configured to detect the gas-borne material. In some embodiments,
the at least one sensors is operatively coupled to the window
and/or the recessed portion. In some embodiments, the enclosure is
configured to maintain an internal atmosphere at a positive
pressure. In some embodiments, the first wall is a ceiling.
[0062] In another aspect, a method for printing a 3D object, the
method comprises: directing an energy beam through a window to
transform a pre-transformed material to a transformed material as
part of the 3D object that is printed in an enclosure comprises a
first wall, which window is disposed in a recessed portion relative
to the first wall, which recessed portion comprises a second wall
that supports the window.
[0063] In some embodiments, the gas-borne material comprises (i) a
portion of the pre-transformed material or (ii) debris associated
with the transforming the pre-transformed material to the
transformed material. In some embodiments, the method further
comprises at least partially shielding the interior surface of the
window from a gas-borne material. In some embodiments, the interior
surface partially defines of an interior volume of the enclosure.
In some embodiments, the gas borne material is produced during the
printing. In some embodiments, the at least partially shielding
comprises passively shielding. In some embodiments, passively
shielding is accomplished by the geometry of the recessed portion.
In some embodiments, the at least partially shielding comprises
actively shielding. In some embodiments, actively shielding
comprises flowing a gas through one or more channels in the second
wall. In some embodiments, actively shielding comprises flowing a
gas from an outlet adjacent to the window. In some embodiments, the
method further comprises controlling flowing of the gas from the
outlet using one or more controllers. In some embodiments,
controlling is during the printing. In some embodiments,
controlling comprises adjusting a velocity and/or a pressure of the
flowing of the gas. In some embodiments, controlling comprises
using an output of one or more sensors. In some embodiments, the
one or more sensors comprise optical sensors. In some embodiments,
controlling comprises using a feedback loop that consider the
output. In some embodiments, the output is indicative of an amount
of the gas borne material in an atmosphere of the enclosure. In
some embodiments, the output is indicative of an amount of the gas
borne material that accumulated on an internal surface of the
window. In some embodiments, flowing the gas is to a direction away
from the window. In some embodiments, the flowing of the gas
results in an undetectable amount of debris affecting a peak
intensity of the energy beam used to transform the pre-transformed
material. In some embodiments, the flowing of the gas results in a
peak intensity of the energy beam being substantially unchanged
after transformation of at least 500 layers of pre-transformed
material. In some embodiments, the flowing of the gas results in a
peak intensity of the energy beam is substantially unchanged after
transformation of at least about 3.4 milliliters of pre-transformed
material. In some embodiments, the at least partially shielding
comprises reducing an amount of the gas-borne material from (i)
altering the energy beam, (ii) obstructing the window, or (iii) a
combination of (i) and (ii). In some embodiments, altering the
energy beam comprises altering a wavelength, power density, or
trajectory thereof. In some embodiments, obstructing the window
comprises adhering to and/or reacting with the window. In some
embodiments, the recessed portion includes a window holder that
supports the window, the method further comprises directing the
energy beam through a cavity of the window holder. In some
embodiments, the recessed portion includes a plurality of window
holders that supports the window, the method further comprises
directing the energy beam between at least two of the plurality of
window holders. In some embodiments, the method further comprises
purging the cavity of the window holder using a flow gas. In some
embodiments, an insubstantial amount of debris affects the printing
of the 3D object. In some embodiments, the energy beam is a first
energy beam and the window is a first window, the method further
comprises directing a second energy beam through a second window.
In some embodiments, the second window is positioned in the
recessed portion. In some embodiments, the second window is
positioned in another recessed portion.
[0064] Another aspect of the present disclosure provides systems,
apparatuses, controllers, and/or non-transitory computer-readable
medium (e.g., software) that implement any of the methods disclosed
herein.
[0065] In another aspect, an apparatus for printing one or more 3D
objects comprises a controller (or controllers) that is/are
programmed to direct a mechanism used in a 3D printing methodology
to implement (e.g., effectuate) any of the method disclosed herein,
wherein the controller is operatively coupled to the mechanism.
[0066] In another aspect, the one or more controllers disclosed
herein comprise a computer software product, e.g., as disclosed
herein.
[0067] In another aspect, a computer software product, comprising a
non-transitory computer-readable medium in which program
instructions are stored, which instructions, when read by a
computer, cause the computer to direct a mechanism used in the 3D
printing process to implement (e.g., effectuate) any of the method
disclosed herein, wherein the non-transitory computer-readable
medium is operatively coupled to the mechanism.
[0068] Another aspect of the present disclosure provides a
non-transitory computer-readable medium comprising
machine-executable code that, upon execution by one or more
computer processors, implements any of the methods disclosed
herein.
[0069] Another aspect of the present disclosure provides a computer
system comprising one or more computer processors and a
non-transitory computer-readable medium coupled thereto. In some
embodiments, the non-transitory computer-readable medium comprises
machine-executable code that, upon execution by the one or more
computer processors, implements any of the methods disclosed
herein.
[0070] Additional aspects and advantages of the present disclosure
will become readily apparent to those skilled in this art from the
following detailed description, wherein only illustrative
embodiments of the present disclosure are shown and described. As
will be realized, the present disclosure is capable of other and
different embodiments, and its several details are capable of
modifications in various obvious respects, all without departing
from the disclosure. Accordingly, the drawings and description are
to be regarded as illustrative in nature, and not as
restrictive.
INCORPORATION BY REFERENCE
[0071] All publications, patents, and patent applications mentioned
in this specification are herein incorporated by reference to the
same extent as if each individual publication, patent, or patent
application was specifically and individually indicated to be
incorporated by reference.
BRIEF DESCRIPTION OF DRAWINGS
[0072] The novel features of the invention are set forth with
particularity in the appended claims. A better understanding of the
features and advantages of the present invention will be obtained
by reference to the following detailed description that sets forth
illustrative embodiments, in which the principles of the invention
are utilized, and the accompanying drawings or figures (also
"FIG.," "FIGs.," "Fig.," and "Figs." herein), of which:
[0073] FIG. 1 schematically illustrates a side view of a
three-dimensional (3D) printer and its components;
[0074] FIG. 2 schematically illustrates a side view of a 3D printer
and its components;
[0075] FIG. 3 schematically illustrates a side view of components
in a 3D printer;
[0076] FIG. 4 schematically illustrates a computer control system
that is programmed or otherwise configured to facilitate the
formation of one or more 3D objects;
[0077] FIG. 5 illustrates a path;
[0078] FIG. 6 illustrates various paths;
[0079] FIGS. 7A-7C schematically illustrates various 3D printer
components;
[0080] FIG. 8 schematically illustrates a side view of a 3D printer
and its components;
[0081] FIG. 9 schematically illustrates a side view of a 3D printer
and its components;
[0082] FIGS. 10A-10D schematically illustrates various 3D printer
components;
[0083] FIGS. 11A-11B schematically illustrates various 3D printer
components;
[0084] FIG. 12 schematically illustrates various 3D printer
components;
[0085] FIG. 13 schematically illustrates various 3D printer
components;
[0086] FIG. 14 schematically illustrates a block diagram of various
3D printer components;
[0087] FIG. 15 schematically illustrates various 3D printer
components;
[0088] FIG. 16 schematically illustrates an example simulation of
gas flow trajectories within across the height and width of an
enclosure as part of the 3D printer;
[0089] FIG. 17 schematically illustrates top view of components of
a 3D printer;
[0090] FIG. 18 schematically illustrates a side view of components
of a 3D printer;
[0091] FIG. 19A-19B each schematically illustrate top view of
components of one or more 3D printers;
[0092] FIG. 20 schematically illustrates various modes of operation
of components of a 3D printer;
[0093] FIG. 21 schematically illustrates a side view of a 3D
printer and its components;
[0094] FIG. 22 schematically illustrates a perspective view of a
component of a 3D printer;
[0095] FIG. 23 schematically illustrates a side view of a 3D
printer and its components;
[0096] FIG. 24 schematically illustrates a side view of a component
of a 3D printer;
[0097] FIG. 25 schematically illustrates a side view of a component
of a 3D printer;
[0098] FIGS. 26A-26E schematically illustrate side views of
components of one or more 3D printers;
[0099] FIGS. 27A-27F schematically illustrate side views of
components of one or more 3D printers;
[0100] FIG. 28 schematically illustrates a side view of 3D printer
components;
[0101] FIGS. 29A-29B each schematically illustrate side views of
components of a 3D printer;
[0102] FIGS. 30A-30D schematically illustrate various cross
sections of one or more 3D printer components;
[0103] FIG. 31 schematically illustrates a side view of a component
of a 3D printer;
[0104] FIGS. 32A-32B schematically illustrate perspective views of
components of one or more 3D printers;
[0105] FIGS. 33A-33E schematically illustrate perspective views of
various components of 3D printers;
[0106] FIGS. 34A and 34B each schematically illustrate various
views of components of a 3D printer;
[0107] FIG. 35 schematically illustrates a top view of an enclosure
of a 3D printer;
[0108] FIGS. 36A-36D schematically illustrate top views of
enclosures of various 3D printers;
[0109] FIG. 37 schematically illustrates a top view of an enclosure
of a 3D printer;
[0110] FIGS. 38A and 38B each schematically illustrate side views
of components of a 3D printer; and
[0111] FIGS. 39A-39C each schematically illustrate top views of an
enclosure of a 3D printer.
[0112] The figures and components therein may not be drawn to
scale. Various components of the figures described herein may not
be drawn to scale.
DETAILED DESCRIPTION
[0113] While various embodiments of the invention have been shown
and described herein, it will be obvious to those skilled in the
art that such embodiments are provided by way of example only.
Numerous variations, changes, and substitutions may occur to those
skilled in the art without departing from the invention. It should
be understood that various alternatives to the embodiments of the
invention described herein might be employed.
[0114] Terms such as "a", "an" and "the" are not intended to refer
to only a singular entity, but include the general class of which a
specific example may be used for illustration. The terminology
herein is used to describe specific embodiments of the
invention(s), but their usage does not delimit the
invention(s).
[0115] When ranges are mentioned, the ranges are meant to be
inclusive, unless otherwise specified. For example, a range between
value 1 and value 2 is meant to be inclusive and include value 1
and value 2. The inclusive range will span any value from about
value 1 to about value 2. The term "adjacent" or "adjacent to," as
used herein, includes `next to`, `adjoining`, `in contact with`,
and `in proximity to.`
[0116] Where suitable, one or more of the features shown in a
figure comprising a 3D printer and/or components thereof can be
combined with one or more of the various features of other 3D
printers and/or components thereof described herein. A figure shown
herein may not show certain features of a 3D printer and/or
components thereof described herein. It should be understood that
any such features can be incorporated within the 3D printer as
desired and where suitable.
[0117] The present disclosure provides three-dimensional (3D)
printing apparatuses, systems, software, and methods for forming a
3D object. For example, a 3D object may be formed by sequential
addition of material or joining of pre-transformed material to form
a structure in a controlled manner (e.g., under manual or automated
control). Pre-transformed material, as understood herein, is a
material before it has been transformed during the 3D printing
process. The transformation can be effectuated by utilizing an
energy beam and/or flux. The pre-transformed material may be a
material that was, or was not, transformed prior to its use in a 3D
printing process. The pre-transformed material may be a starting
material for the 3D printing process.
[0118] In a 3D printing process, the deposited pre-transformed
material may be fused, (e.g., sintered or melted), bound or
otherwise connected to form at least a portion of the desired 3D
object. Fusing, binding or otherwise connecting the material is
collectively referred to herein as "transforming" the material.
Fusing the material may refer to melting, smelting, or sintering a
pre-transformed material.
[0119] Melting may comprise liquefying the material (i.e.,
transforming to a liquefied state). A liquefied state refers to a
state in which at least a portion of a transformed material is in a
liquid state. Melting may comprise liquidizing the material (i.e.,
transforming to a liquidus state). A liquidus state refers to a
state in which an entire transformed material is in a liquid state.
The apparatuses, methods, software, and/or systems provided herein
are not limited to the generation of a single 3D object, but are
may be utilized to generate one or more 3D objects simultaneously
(e.g., in parallel) or separately (e.g., sequentially). The
multiplicity of 3D object may be formed in one or more material
beds (e.g., powder bed). In some embodiments, a plurality of 3D
objects is formed in one material bed.
[0120] In some examples, 3D printing methodologies comprise
extrusion, wire, granular, laminated, light polymerization, or
powder bed and inkjet head 3D printing. Extrusion 3D printing can
comprise robo-casting, fused deposition modeling (FDM) or fused
filament fabrication (FFF). Wire 3D printing can comprise electron
beam freeform fabrication (EBF3). Granular 3D printing can comprise
direct metal laser sintering (DMLS), electron beam melting (EBM),
selective laser melting (SLM), selective heat sintering (SHS), or
selective laser sintering (SLS). Powder bed and inkjet head 3D
printing can comprise plaster-based 3D printing (PP). Laminated 3D
printing can comprise laminated object manufacturing (LOM). Light
polymerized 3D printing can comprise stereo-lithography (SLA),
digital light processing (DLP), or laminated object manufacturing
(LOM). 3D printing methodologies can comprise Direct Material
Deposition (DMD). The Direct Material Deposition may comprise,
Laser Metal Deposition (LMD, also known as, Laser deposition
welding). 3D printing methodologies can comprise powder feed, or
wire deposition.
[0121] In some examples, 3D printing methodologies differ from
methods traditionally used in semiconductor device fabrication
(e.g., vapor deposition, etching, annealing, masking, or molecular
beam epitaxy). In some instances, 3D printing may further comprise
one or more printing methodologies that are traditionally used in
semiconductor device fabrication. 3D printing methodologies can
differ from vapor deposition methods such as chemical vapor
deposition, physical vapor deposition, or electrochemical
deposition. In some instances, 3D printing may further include
vapor deposition methods.
[0122] In some embodiments, the deposited pre-transformed material
within the enclosure is a liquid material, semi-solid material
(e.g., gel), or a solid material (e.g., powder). The deposited
pre-transformed material within the enclosure can be in the form of
a powder, wires, sheets, or droplets. The material (e.g.,
pre-transformed, transformed, and/or hardened) may comprise
elemental metal, metal alloy, ceramics, or an allotrope of
elemental carbon. The allotrope of elemental carbon may comprise
amorphous carbon, graphite, graphene, diamond, or fullerene. The
fullerene may be selected from the group consisting of a spherical,
elliptical, linear, and tubular fullerene. The fullerene may
comprise a buckyball, or a carbon nanotube. The ceramic material
may comprise cement. The ceramic material may comprise alumina,
zirconia, or carbide (e.g., silicon carbide, or tungsten carbide).
The ceramic material may include high performance material (HPM).
The ceramic material may include a nitride (e.g., boron nitride or
aluminum nitride). The material may comprise sand, glass, or stone.
In some embodiments, the material may comprise an organic material,
for example, a polymer or a resin (e.g., 114 W resin). The organic
material may comprise a hydrocarbon. The polymer may comprise
styrene or nylon (e.g., nylon 11). The polymer may comprise a
thermoplast. The organic material may comprise carbon and hydrogen
atoms. The organic material may comprise carbon and oxygen atoms.
The organic material may comprise carbon and nitrogen atoms. The
organic material may comprise carbon and sulfur atoms. In some
embodiments, the material may exclude an organic material. The
material may comprise a solid or a liquid. In some embodiments, the
material may comprise a silicon-based material, for example,
silicon based polymer or a resin. The material may comprise an
organosilicon-based material. The material may comprise silicon and
hydrogen atoms. The material may comprise silicon and carbon atoms.
In some embodiments, the material may exclude a silicon-based
material. The powder material may be coated by a coating (e.g.,
organic coating such as the organic material (e.g., plastic
coating)). The material may be devoid of organic material. The
liquid material may be compartmentalized into reactors, vesicles,
or droplets. The compartmentalized material may be
compartmentalized in one or more layers. The material may be a
composite material comprising a secondary material. The secondary
material can be a reinforcing material (e.g., a material that forms
a fiber). The reinforcing material may comprise a carbon fiber,
Kevlar.RTM., Twaron.RTM., ultra-high-molecular-weight polyethylene,
or glass fiber. The material can comprise powder (e.g., granular
material) and/or wires. The bound material can comprise chemical
bonding. Transforming can comprise chemical bonding. Chemical
bonding can comprise covalent bonding. The pre-transformed material
may be pulverous. The printed 3D object can be made of a single
material (e.g., single material type) or multiple materials (e.g.,
multiple material types). Sometimes one portion of the 3D object
and/or of the material bed may comprise one material, and another
portion may comprise a second material different from the first
material. The material may be a single material type (e.g., a
single alloy or a single elemental metal). The material may
comprise one or more material types. For example, the material may
comprise two alloys, an alloy and an elemental metal, an alloy and
a ceramic, or an alloy and an elemental carbon. The material may
comprise an alloy and alloying elements (e.g., for inoculation).
The material may comprise blends of material types. The material
may comprise blends with elemental metal or with metal alloy. The
material may comprise blends excluding (e.g., without) elemental
metal or including (e.g., with) metal alloy. The material may
comprise a stainless steel. The material may comprise a titanium
alloy, aluminum alloy, and/or nickel alloy.
[0123] In some cases, a layer within the 3D object comprises a
single type of material. In some examples, a layer of the 3D object
may comprise a single elemental metal type, or a single alloy type.
In some examples, a layer within the 3D object may comprise several
types of material (e.g., an elemental metal and an alloy, an alloy
and a ceramic, an alloy and an elemental carbon). In certain
embodiments, each type of material comprises only a single member
of that type. For example: a single member of elemental metal
(e.g., iron), a single member of metal alloy (e.g., stainless
steel), a single member of ceramic material (e.g., silicon carbide
or tungsten carbide), or a single member of elemental carbon (e.g.,
graphite). In some cases, a layer of the 3D object comprises more
than one type of material. In some cases, a layer of the 3D object
comprises more than member of a type of material.
[0124] In some examples the material bed, build platform (also
referred to herein as platform), or both material bed and platform
comprise a material type which constituents (e.g., atoms) readily
lose their outer shell electrons, resulting in a free-flowing cloud
of electrons within their otherwise solid arrangement. In some
examples the powder, the base, or both the powder and the base
comprise a material characterized in having high electrical
conductivity, low electrical resistivity, high thermal
conductivity, or high density. The high electrical conductivity can
be at least about 1*10.sup.5 Siemens per meter (S/m), 5*10.sup.5
S/m, 1*10.sup.6 S/m, 5*10.sup.6 S/m, 1*10.sup.7 S/m, 5*10.sup.7
S/m, or 1*10.sup.8 S/m. The symbol "*" designates the mathematical
operation "times." The high electrical conductivity can be between
any of the afore-mentioned electrical conductivity values (e.g.,
from about 1*10.sup.5 S/m to about 1*10.sup.8 S/m). The thermal
conductivity, electrical resistivity, electrical conductivity,
and/or density can be measured at ambient temperature (e.g., at
R.T., or 20.degree. C.). The low electrical resistivity may be at
most about 1*10.sup.-5 ohm times meter (.OMEGA.m), 5*10.sup.-6
.OMEGA.*m, 1*10.sup.-6 .OMEGA.*m, 5*10.sup.-7 .OMEGA.*m,
1*10.sup.-7 .OMEGA.*m, 5*10.sup.-8 or 1*10.sup.-8 .OMEGA.*m. The
low electrical resistivity can be between any of the
afore-mentioned values (e.g., from about 1.times.10.sup.-5
.OMEGA.*m to about 1.times.10.sup.-8 .OMEGA.*m). The high thermal
conductivity may be at least about 10 Watts per meter times Kelvin
(W/mK), 15 W/mK, 20 W/mK, 35 W/mK, 50 W/mK, 100 W/mK, 150 W/mK, 200
W/mK, 205 W/mK, 300 W/mK, 350 W/mK, 400 W/mK, 450 W/mK, 500 W/mK,
550 W/mK, 600 W/mK, 700 W/mK, 800 W/mK, 900 W/mK, or 1000 W/mK. The
high thermal conductivity can be between any of the afore-mentioned
thermal conductivity values (e.g., from about 20 W/mK to about 1000
W/mK). The high density may be at least about 1.5 grams per cubic
centimeter (g/cm.sup.3), 1.7 g/cm.sup.3, 2 g/cm.sup.3, 2.5
g/cm.sup.3, 2.7 g/cm.sup.3, 3 g/cm.sup.3, 4 g/cm.sup.3, 5
g/cm.sup.3, 6 g/cm.sup.3, 7 g/cm.sup.3, 8 g/cm.sup.3, 9 g/cm.sup.3,
10 g/cm.sup.3, 11 g/cm.sup.3, 12 g/cm.sup.3, 13 g/cm.sup.3, 14
g/cm.sup.3, 15 g/cm.sup.3, 16 g/cm.sup.3, 17 g/cm.sup.3, 18
g/cm.sup.3, 19 g/cm.sup.3, 20 g/cm.sup.3, or 25 g/cm.sup.3. The
high density can be any value between the afore mentioned values
(e.g., from about 1 g/cm.sup.3 to about 25 g/cm.sup.3).
[0125] In some embodiments, the elemental metal is an alkali metal,
an alkaline earth metal, a transition metal, a rare-earth element
metal, or another metal. The alkali metal can be Lithium, Sodium,
Potassium, Rubidium, Cesium, or Francium. The alkali earth metal
can be Beryllium, Magnesium, Calcium, Strontium, Barium, or Radium.
The transition metal can be Scandium, Titanium, Vanadium, Chromium,
Manganese, Iron, Cobalt, Nickel, Copper, Zinc, Yttrium, Zirconium,
Platinum, Gold, Rutherfordium, Dubnium, Seaborgium, Bohrium,
Hassium, Meitnerium, Ununbium, Niobium, Iridium, Molybdenum,
Technetium, Ruthenium, Rhodium, Palladium, Silver, Cadmium,
Hafnium, Tantalum, Tungsten, Rhenium or Osmium. The transition
metal can be mercury. The rare-earth metal can be a lanthanide or
an actinide. The antinode metal can be Lanthanum, Cerium,
Praseodymium, Neodymium, Promethium, Samarium, Europium,
Gadolinium, Terbium, Dysprosium, Holmium, Erbium, Thulium,
Ytterbium, or Lutetium. The actinide metal can be Actinium,
Thorium, Protactinium, Uranium, Neptunium, Plutonium, Americium,
Curium, Berkelium, Californium, Einsteinium, Fermium, Mendelevium,
Nobelium, or Lawrencium. The other metal can be Aluminum, Gallium,
Indium, Tin, Thallium, Lead, or Bismuth. The material may comprise
a precious metal. The precious metal may comprise gold, silver,
palladium, ruthenium, rhodium, osmium, iridium, or platinum. The
material may comprise at least about 40%, 50%, 60%, 70%, 80%, 90%,
95%, 97%, 98%, 99%, 99.5% or more precious metal. The powder
material may comprise at most about 40%, 50%, 60%, 70%, 80%, 90%,
95%, 97%, 98%, 99%, 99.5% or less precious metal. The material may
comprise precious metal with any value in between the
afore-mentioned values. The material may comprise at least a
minimal percentage of precious metal according to the laws in the
particular jurisdiction.
[0126] In some embodiments, the metal alloy comprises iron based
alloy, nickel based alloy, cobalt based alloy, chrome based alloy,
cobalt chrome based alloy, titanium based alloy, magnesium based
alloy, or copper based alloy. The alloy may comprise an oxidation
or corrosion resistant alloy. The alloy may comprise a super alloy
(e.g., Inconel). The super alloy may comprise Inconel 600, 617,
625, 690, 718 or X-750. The alloy may comprise an alloy used for
aerospace applications, automotive application, surgical
application, or implant applications. The metal may include a metal
used for aerospace applications, automotive application, surgical
application, or implant applications. The super alloy may comprise
IN 738 LC, IN 939, Rene 80, IN 6203 (e.g., IN 6203 DS), PWA 1483
(e.g., PWA 1483 SX), or Alloy 247.
[0127] In some embodiments, the metal alloys are Refractory Alloys.
The refractory metals and alloys may be used for heat coils, heat
exchangers, furnace components, or welding electrodes. The
Refractory Alloys may comprise a high melting points, low
coefficient of expansion, mechanically strong, low vapor pressure
at elevated temperatures, high thermal conductivity, or high
electrical conductivity.
[0128] In some embodiments, the material (e.g., alloy or elemental)
comprises a material used for applications in industries comprising
aerospace (e.g., aerospace super alloys), jet engine, missile,
automotive, marine, locomotive, satellite, defense, oil & gas,
energy generation, semiconductor, fashion, construction,
agriculture, printing, or medical. The material may comprise an
alloy used for products comprising, devices, medical devices (human
& veterinary), machinery, cell phones, semiconductor equipment,
generators, engines, pistons, electronics (e.g., circuits),
electronic equipment, agriculture equipment, motor, gear,
transmission, communication equipment, computing equipment (e.g.,
laptop, cell phone, i-pad), air conditioning, generators,
furniture, musical equipment, art, jewelry, cooking equipment, or
sport gear. The material may comprise an alloy used for products
for human or veterinary applications comprising implants, or
prosthetics. The metal alloy may comprise an alloy used for
applications in the fields comprising human or veterinary surgery,
implants (e.g., dental), or prosthetics.
[0129] In some embodiments, the alloy includes a high-performance
alloy. The alloy may include an alloy exhibiting at least one of
excellent mechanical strength, resistance to thermal creep
deformation, good surface stability, resistance to corrosion, and
resistance to oxidation. The alloy may include a face-centered
cubic austenitic crystal structure. The alloy may comprise
Hastelloy, Inconel, Waspaloy, Rene alloy (e.g., Rene-80, Rene-77,
Rene-220, or Rene-41), Scandium alloy, Haynes alloy, Incoloy,
MP98T, TMS alloy, MTEK (e.g., MTEK grade MAR-M-247, MAR-M-509,
MAR-M-R41, or MAR-M-X-45), or CMSX (e.g., CMSX-3, or CMSX-4). The
alloy can be a single crystal alloy.
[0130] In some instances, the iron-based alloy comprises Elinvar,
Fernico, Ferroalloys, Invar, Iron hydride, Kovar, Spiegeleisen,
Staballoy (stainless steel), or Steel. In some instances, the metal
alloy is steel. The Ferroalloy may comprise Ferroboron,
Ferrocerium, Ferrochrome, Ferromagnesium, Ferromanganese,
Ferromolybdenum, Ferronickel, Ferrophosphorus, Ferrosilicon,
Ferrotitanium, Ferrouranium, or Ferrovanadium. The iron-based alloy
may include cast iron or pig iron. The steel may include Bulat
steel, Chromoly, Crucible steel, Damascus steel, Hadfield steel,
High speed steel, HSLA steel, Maraging steel, Maraging Steel
(M300), Reynolds 531, Silicon steel, Spring steel, Stainless steel,
Tool steel, Weathering steel, or Wootz steel. The high-speed steel
may include Mushet steel. The stainless steel may include AL-6XN,
Alloy 20, celestrium, marine grade stainless, Martensitic stainless
steel, surgical stainless steel, or Zeron 100. The tool steel may
include Silver steel. The steel may comprise stainless steel,
Nickel steel, Nickel-chromium steel, Molybdenum steel, Chromium
steel, Chromium-vanadium steel, Tungsten steel,
Nickel-chromium-molybdenum steel or Silicon-manganese steel. The
steel may be comprised of any Society of Automotive Engineers (SAE)
grade such as 440F, 410, 312, 430, 440A, 440B, 440C, 304, 305,
304L, 304L, 301, 304LN, 301LN, 2304, 316, 316LN, 316L, 317L, 2205,
409, 904L, 321, 254SMO, 316Ti, 321H, 17-4, 15-5, 420 or 304H. The
steel may comprise stainless steel of at least one crystalline
structure selected from the group consisting of austenitic,
superaustenitic, ferritic, martensitic, duplex and
precipitation-hardening martensitic. Duplex stainless steel may be
lean duplex, standard duplex, super duplex or hyper duplex. The
stainless steel may comprise surgical grade stainless steel (e.g.,
austenitic 316, martensitic 420 or martensitic 440). The austenitic
316 stainless steel may include 316L or 316LVM. The steel may
include 17-4 Precipitation Hardening steel (also known as type 630
is a chromium-copper precipitation hardening stainless steel;
17-4PH steel). The stainless steel may comprise 360L stainless
steel.
[0131] In some embodiments, the titanium-based alloys include alpha
alloys, near alpha alloys, alpha and beta alloys, or beta alloys.
The titanium alloy may comprise grade 1, 2, 2H, 3, 4, 5, 6, 7, 7H,
8, 9, 10, 11, 12, 13, 14, 15, 16, 16H, 17, 18, 19, 20, 21, 2, 23,
24, 25, 26, 26H, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38 or
higher. In some instances, the titanium base alloy includes
TiAl.sub.6V.sub.4 or TiAl.sub.6Nb.sub.7.
[0132] In some embodiments, the Nickel based alloy includes Alnico,
Alumel, Chromel, Cupronickel, Ferronickel, German silver,
Hastelloy, Inconel, Monel metal, Nichrome, Nickel-carbon, Nicrosil,
Nisil, Nitinol, Hastelloy X, Cobalt-Chromium or Magnetically "soft"
alloys. The magnetically "soft" alloys may comprise Mu-metal,
Permalloy, Supermalloy, or Brass. The Brass may include nickel
hydride, stainless or coin silver. The cobalt alloy may include
Megallium, Stellite (e. g. Talonite), Ultimet, or Vitallium. The
chromium alloy may include chromium hydroxide, or Nichrome.
[0133] In some embodiments, the aluminum-based alloy includes
AA-8000, Al--Li (aluminum-lithium), Alnico, Duralumin, Hiduminium,
Kryron Magnalium, Nambe, Scandium-aluminum, or, Y alloy. The
magnesium alloy may be Elektron, Magnox or T-Mg--Al--Zn (Bergman
phase) alloy. At times, the material excludes at least one
aluminum-based alloy (e.g., AlSi.sub.10Mg).
[0134] In some embodiments, the copper based alloy comprises
Arsenical copper, Beryllium copper, Billon, Brass, Bronze,
Constantan, Copper hydride, Copper-tungsten, Corinthian bronze,
Cunife, Cupronickel, Cymbal alloys, Devarda's alloy, Electrum,
Hepatizon, Heusler alloy, Manganin, Molybdochalkos, Nickel silver,
Nordic gold, Shakudo or Tumbaga. The Brass may include Calamine
brass, Chinese silver, Dutch metal, Gilding metal, Muntz metal,
Pinchbeck, Prince's metal, or Tombac. The Bronze may include
Aluminum bronze, Arsenical bronze, Bell metal, Florentine bronze,
Guanin, Gunmetal, Glucydur, Phosphor bronze, Ormolu or Speculum
metal. The copper alloy may be a high-temperature copper alloy
(e.g., GRCop-84).
[0135] In some embodiments, the elemental carbon comprises
graphite, Graphene, diamond, amorphous carbon, carbon fiber, carbon
nanotube, or fullerene.
[0136] In some embodiments, the material comprises powder material
(also referred to herein as a "pulverous material"). The powder
material may comprise a solid comprising fine particles. The powder
may be a granular material. The powder can be composed of
individual particles. At least some of the particles can be
spherical, oval, prismatic, cubic, or irregularly shaped. At least
some of the particles can have a fundamental length scale (e.g.,
diameter, spherical equivalent diameter, length, width, depth, or
diameter of a bounding sphere). The fundamental length scale
(abbreviated herein as "FLS") of at least some of the particles can
be from about 1 nanometers (nm) to about 1000 micrometers
(microns), 500 microns, 400 microns, 300 microns, 200 microns, 100
microns, 50 microns, 40 microns, 30 microns, 20 microns, 10
microns, 1 micron, 500 nm, 400 nm, 300 nm, 200 nm, 100 nm, 50 nm,
40 nm, 30 nm, 20 nm, 10 nm, or 5 nm. At least some of the particles
can have a FLS of at least about 1000 micrometers (microns), 500
microns, 400 microns, 300 microns, 200 microns, 100 microns, 50
microns, 40 microns, 30 microns, 20 microns, 10 microns, 1 micron,
500 nm, 400 nm, 300 nm, 200 nm, 100 nm, 50 nm, 40 nm, 30 nm, 20 nm,
10 nm, 5 nanometers (nm) or more. At least some of the particles
can have a FLS of at most about 1000 micrometers (microns), 500
microns, 400 microns, 300 microns, 200 microns, 100 microns, 50
microns, 40 microns, 30 microns, 20 microns, 10 microns, 1 micron,
500 nm, 400 nm, 300 nm, 200 nm, 100 nm, 50 nm, 40 nm, 30 nm, 20 nm,
10 nm, 5 nm or less. In some cases, at least some of the powder
particles may have a FLS in between any of the afore-mentioned
FLSs.
[0137] In some embodiments, the powder comprises a particle
mixture, which particle comprises a shape. The powder can be
composed of a homogenously shaped particle mixture such that all of
the particles have substantially the same shape and FLS magnitude
within at most about 1%, 5%, 8%, 10%, 15%, 20%, 25%, 30%, 35%, 40%,
50%, 60%, 70%, or less distribution of FLS. In some cases, the
powder can be a heterogeneous mixture such that the particles have
variable shape and/or FLS magnitude. In some examples, at least
about 30%, 40%, 50%, 60%, or 70% (by weight) of the particles
within the powder material have a largest FLS that is smaller than
the median largest FLS of the powder material. In some examples, at
least about 30%, 40%, 50%, 60%, or 70% (by weight) of the particles
within the powder material have a largest FLS that is smaller than
the mean largest FLS of the powder material.
[0138] In some examples, the size of the largest FLS of the
transformed material (e.g., height) is greater than the average
largest FLS of the powder material by at least about 1.1 times, 1.2
times, 1.4 times, 1.6 times, 1.8 times, 2 times, 4 times, 6 times,
8 times, or 10 times. In some examples, the size of the largest FLS
of the transformed material is greater than the median largest FLS
of the powder material by at most about 1.1 times, 1.2 times, 1.4
times, 1.6 times, 1.8 times, 2 times, 4 times, 6 times, 8 times, or
10 times. The powder material can have a median largest FLS that is
at least about 1 .mu.m, 5 .mu.m, 10 .mu.m, 20 .mu.m, 30 .mu.m, 40
.mu.m, 50 .mu.m, 100 .mu.m, or 200 .mu.m. The powder material can
have a median largest FLS that is at most about 1 .mu.m, 5 .mu.m,
10 .mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m, 100 .mu.m, or 200
.mu.m. In some cases, the powder particles may have a FLS in
between any of the FLS listed above (e.g., from about 1 .mu.m to
about 200 .mu.m, from about 1 .mu.m to about 50 .mu.m, or from
about 5 .mu.m to about 40 .mu.m).
[0139] In another aspect provided herein is a system for generating
a 3D object comprising: an enclosure for accommodating at least one
layer of pre-transformed material (e.g., powder); an energy (e.g.,
energy beam) capable of transforming the pre-transformed material
to form a transformed material; and a controller that directs the
energy to at least a portion of the layer of pre-transformed
material according to a path (e.g., as described herein). The
transformed material may be capable of hardening to form at least a
portion of a 3D object. The system may comprise an energy source,
an optical system (e.g., FIG. 3), a temperature control system, a
material delivery mechanism (e.g., a recoater), a pressure control
system, an atmosphere control system, an atmosphere, a pump, a
nozzle, a valve, a sensor, a central processing unit, a display, a
chamber, or an algorithm. The chamber may comprise a building
platform. The system for generating a 3D object and its components
may be any 3D printing system such as, for example, the one
described in Patent Application serial number PCT/US15/36802 filed
on Jun. 19, 2015, titled "APPARATUSES, SYSTEMS AND METHODS FOR
THREE-DIMENSIONAL PRINTING" or in Provisional Patent Application
Ser. No. 62/317,070 filed Apr. 1, 2016, titled "APPARATUSES,
SYSTEMS AND METHODS FOR EFFICIENT THREE-DIMENSIONAL PRINTING", both
of which are entirely incorporated herein by references.
[0140] In some embodiments, the 3D printing system comprises a
chamber (e.g., FIG. 1, 116; FIG. 2, 216). The chamber may be
referred herein as the "processing chamber." The processing chamber
may comprise an energy beam (e.g., FIG. 1, 101; FIG. 2, 204). The
energy beam may be directed towards an exposed surface of a
material bed (e.g., FIG. 1, 119). The 3D printing system may
comprise one or more modules (e.g., FIG. 2, 201, 202, and 203). The
one or more modules may be referred herein as the "build modules."
At times, at least one build module (e.g., FIG. 1, 123) may be
situated in the enclosure comprising the processing chamber (e.g.,
FIG. 1, 116). At times, at least one build module may engage with
the processing chamber (e.g., FIG. 1). At times, at least one build
module may not engage with the processing chamber (e.g., FIG. 2).
At times, a plurality of build modules (e.g., FIG. 2, 201, 202, and
203) may be situated in an enclosure (e.g., FIG. 2, 200) comprising
the processing chamber (e.g., FIG. 2, 210). The build module may
reversibly engage with (e.g., couple to) the processing chamber.
The engagement of the build module with the processing chamber may
be controlled (e.g., by a controller). The control may be automatic
and/or manual. The engagement of the build module with the
processing chamber may be reversible. In some embodiments, the
engagement of the build module with the processing chamber may be
permanent. The FLS (e.g., width, depth, and/or height) of the
processing chamber and/or the build plate can be at least about 50
millimeters (mm), 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 250
mm, 280 mm, 320 mm, 400 mm, 450 mm, 500 mm, 800 mm, 900 mm, 1 meter
(m), 2 m, or 5 m. The FLS of the processing chamber and/or the
build plate can be at most about 50 millimeters (mm), 60 mm, 70 mm,
80 mm, 90 mm, 100 mm, 200 mm, 250 mm, 400 mm, 500 mm, 800 mm, 900
mm, 1 meter (m), 2 m, or 5 m. The FLS of the processing chamber
and/or the build plate can be between any of the afore-mentioned
values (e.g., 50 mm to about 5 m, from about 250 mm to about 500
mm, or from about 500 mm to about 5 m).
[0141] In some embodiments, the build module is operatively coupled
to at least one controller. At least one of the build modules may
have a controller. The controller may be its own controller. The
controller may be different than the controller controlling the 3D
printing process and/or the processing chamber. The translation
facilitator (e.g., build module delivery system) may comprise a
controller (e.g., its own controller). The controller of the
translation facilitator may be different than the controller
controlling the 3D printing process and/or the processing chamber.
The controller of the translation facilitator may be different than
the controller of the build module. The build module controller
and/or the translation facilitator controller may be a
microcontroller. At times, the controller of the 3D printing
process and/or the processing chamber may not interact with the
controller of the build module and/or translation facilitator. At
times, the controller of the build module and/or translation
facilitator may not interact with the controller of the 3D printing
process and/or the processing chamber. For example, the controller
of the build module may not interact with the controller of the
processing chamber. For example, the controller of the translation
facilitator may not interact with the controller of the processing
chamber. The controller of the 3D printing process and/or the
processing chamber may be able to interpret one or more signals
emitted from (e.g., by) the build module and/or translation
facilitator. The controller of the build module and/or translation
facilitator may be able to interpret one or more signals emitted
from (e.g., by) the processing chamber. The one or more signals may
be electromagnetic, electronic, magnetic, pressure, or sound
signals. The electromagnetic signals may comprise visible light,
infrared, ultraviolet, or radio frequency signals. The
electromagnetic signals may comprise a radio frequency
identification signal (RFID). The RFID may be specific for a build
module, user, entity, 3D object model, processor, material type,
printing instruction, 3D print job, or any combination thereof.
[0142] In some examples, the build module controller controls the
translation of the build module, sealing status of the build
module, atmosphere of the build module, engagement of the build
module with the processing chamber, exit of the build module from
the enclosure, entry of the build module into the enclosure, or any
combination thereof. Controlling the sealing status of the build
module may comprise opening or closing of the build module shutter.
The build chamber controller may be able to interpret signals from
the 3D printing controller and/or processing chamber controller.
The processing chamber controller may be the 3D printing
controller. For example, the build module controller may be able to
interpret and/or respond to a signal regarding the atmospheric
conditions in the load lock. For example, the build module
controller may be able to interpret and/or respond to a signal
regarding the completion of a 3D printing process (e.g., when the
printing of a 3D object is complete). The build module may be
connected to an actuator. The actuator may be translating or
stationary. The controller of the build module may direct the
translation facilitator (e.g., actuator) to translate the build
module from one position to another (e.g., arrows 221-224 in FIG.
2), when translation is possible. The translation facilitator may
be a build module delivery system. The translation facilitator may
be autonomous. The translation facilitator may operate
independently of the 3D printer (e.g., mechanisms directed by the
3D printing controller). The translation facilitator (e.g., build
module delivery system) may comprise a controller and/or a motor.
The translation facilitator may comprise a machine or a human. The
translation is possible, for example, when the destination position
of the build module is empty. The controller of the 3D printing
and/or the processing chamber may be able to sense signals emitted
from the controller of the build module. For example, the
controller of the 3D printing and/or the processing chamber may be
able to sense a signal from the build module that is emitted when
the build module is docked into engagement position with the
processing chamber. The signal from the build module may comprise
reaching a certain position in space, reaching a certain
atmospheric characteristic threshold, opening or shutting the build
platform closing, or engaging or disengaging (e.g., docking or
undocking) from the processing chamber. The build module may
comprise one or more sensors. For example, the build module may
comprise a proximity, movement, light, sounds, or touch sensor.
[0143] In some embodiments, the build module is included as part of
the 3D printing system. In some embodiments, the build module is
separate from the 3D printing system. The build module may be
independent (e.g., operate independently) from the 3D printing
system. For example, build module may comprise its own controller,
motor, elevator, build platform, valve, channel, and/or shutter. In
some embodiments, one or more conditions differ between the build
module and the processing chamber, and/or among the different build
modules. The difference may comprise different pre-transformed
materials, atmospheres, platforms, temperatures, pressures,
humidity levels, an oxidizing gas (e.g., oxygen) level, gas type
(e.g., inert), traveling speed (e.g., of the build modules),
traveling method (e.g., of the build modules), acceleration speed
(e.g., of the build modules), or post processing treatment (e.g.,
within the processing chamber and/or build module(s)). The
difference may comprise different reactive agent levels. The term
"gas" may comprise one or more gasses. For example, the relative
velocity of the various build modules with respect to the
processing chamber may be different, similar, or substantially
similar. The build platform may undergo different, similar, or
substantially similar post processing treatment (e.g., further
processing of the 3D object and/or material bed after the
generation of the 3D object in the material bed is complete).
[0144] In some examples, at least one build module translates
relative to the processing chamber. The translation may be parallel
or substantially parallel to the bottom surface of the build
chamber. The bottom surface of the build chamber is the one closest
to the gravitational center. The translation may be at an angle
(e.g., planar or compound) relative to the bottom surface of the
build chamber. The translation may use any device that facilitates
translation (e.g., an actuator). For example, the translation
facilitator may comprise a robotic arm, conveyor (e.g., conveyor
belt), rotating screw, or a moving surface (e.g., platform). The
translation facilitator may comprise a chain, rail, motor, or an
actuator. The translation facilitator may comprise a component that
can move another. The movement may be controlled (e.g., using a
controller). The movement may comprise using a control signal and
source of energy (e.g., electricity). The translation facilitator
may use electricity, pneumatic pressure, hydraulic pressure, or
human power.
[0145] In some embodiments, the 3D printing system comprises a
plurality of build modules. The 3D printing system may comprise at
least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 build modules. FIG. 2 shows
an example of three build modules (e.g., 201, 202, and 203) and one
processing chamber 210. Examples of enclosures, build modules,
unpacking stations, processing chambers and their components can be
found in PCT patent application serial number PCT/US17/39422, which
is incorporated herein by reference in its entirety.
[0146] In some examples, at least one build module engages with the
processing chamber to expand the interior volume of the processing
chamber (e.g., into the volume of the engaged build module). During
at least a portion of the 3D printing process, the atmospheres of
the chamber and enclosure may merge. At times, during at least a
portion of the 3D printing process, the atmospheres of the chamber
and enclosure may remain separate. During at least a portion of the
3D printing process, the atmospheres of the build module and
processing chamber may be separate. The build module may be mobile
or stationary. The build module may comprise an elevator. The
elevator may be connected to a platform (e.g., building platform).
The elevator may be reversibly connected to at least a portion of
the platform (e.g., to the base). The elevator may be irreversibly
connected to at least a portion of the platform (e.g., to the
substrate). The platform may be separated from one or more walls
(e.g., side walls) of the build module by a seal (e.g., FIG. 2,
211; FIG. 1, 103). The seal may be impermeable or substantially
impermeable to gas. The seal may be permeable to gas. The seal may
be flexible. The seal may be elastic. The seal may be bendable. The
seal may be compressible. The seal may comprise rubber (e.g.,
latex), Teflon, plastic, or silicon. The seal may comprise a mesh,
membrane, sieve, paper (e.g., filter paper), cloth (e.g., felt), or
brush. The mesh, membrane, paper and/or cloth may comprise randomly
and/or non-randomly arranged fibers. The paper may comprise a
High-efficiency particulate arrestance filter (TEPA) filter. The
seal may be permeable to at least one gas, and impermeable to the
pre-transformed (e.g., and to the transformed) material. The seal
may not allow a pre-transformed (e.g., and to the transformed)
material to pass through.
[0147] In some examples, the build module and/or processing chamber
comprises an openable shutter. For example, the build module and
processing chamber may each comprise a separate openable shutter.
The shutter may be a seal, door, blockade, stopple, stopper, plug,
piston, cover, roof, hood, block, stopple, obstruction, lid,
closure, or a cap. The shutter may be opened upon engagement of the
build module with the processing chamber. FIG. 1 shows an example
of a processing chamber (e.g., FIG. 1, 126) and a build module
(e.g., FIG. 1, 123). The processing chamber comprises the energy
beam (e.g., FIG. 1, 101). The build module comprises a build
platform comprising a substrate (e.g., FIG. 1, 109), a base (e.g.,
FIG. 1, 102), and an elevator shaft (e.g., FIG. 1, 105) that allows
the platform to move vertically up and down. The build module
(e.g., FIG. 1, 123) may comprise a shutter. The processing chamber
may comprise a shutter. The shutter may be openable. The shutter
may be removable. The removal of the shutter may comprise manual or
automatic removal. The build module shutter may be opened while
being connected to the build module. The processing chamber shutter
may be opened while being connected to the processing chamber
(e.g., through connector). The shutter connector may comprise a
hinge, chain, or a rail. In an example, the shutter may be opened
in a manner similar to opening a door or a window. The shutter may
be opened by swiveling (e.g., similar to opening a door or a window
held on a hinge). The shutter may be opened by its removal from the
opening which it blocks. The removal may be guided (e.g., by a
rail, arm, pulley, crane, or conveyor). The guiding may be using a
robot. The guiding may be using at least one motor and/or gear. The
shutter may be opened while being disconnected from the build
module. For example, the shutter may be opened similar to opening a
lid. The shutter may be opened by shifting or sliding (e.g., to a
side).
[0148] In some embodiments, the build module, processing chamber,
and/or enclosure comprises one or more seals. The seal may be a
sliding seal or a top seal. For example, the build module and/or
processing chamber may comprise a sliding seal that meets with the
exterior of the build module upon engagement of the build module
with the processing chamber. For example, the processing chamber
may comprise a top seal that faces the build module and is pushed
upon engagement of the processing chamber with the build module.
For example, the build module may comprise a top seal that faces
the processing chamber and is pushed upon engagement of the
processing chamber with the build module. The seal may be a face
seal, or compression seal. The seal may comprise an O-ring.
[0149] In some embodiments, the build module, processing chamber,
and/or enclosure is sealed, sealable, or open. The atmosphere of
the build module, processing chamber, and/or enclosure may be
regulated. The build module may be sealed, sealable, or open. The
processing chamber may be sealed, sealable, or open. The enclosure
may be sealed, sealable, or open. The build module, processing
chamber, and/or enclosure may comprise a valve and/or a gas
opening-port. The valve and/or a gas opening-port may be below, or
above the building platform. The valve and/or a gas opening-port
may be disposed at the horizontal plane of the build platform. The
valve and/or a gas opening-port may be disposed at the adjacent to
the build platform. The valve may allow at least one gas to travel
through. The gas may enter or exit through the valve. For example,
the gas may enter or exit the build module, processing chamber,
and/or enclosure through the valve. In some embodiments, the
atmosphere of the build module, processing chamber, and/or
enclosure may be individually controlled. In some embodiments, the
atmosphere of at least two of the build module, processing chamber,
and enclosure may be separately controlled. In some embodiments,
the atmosphere of at least two of the build module, processing
chamber, and enclosure may be controlled in concert (e.g.,
simultaneously). In some embodiments, the atmosphere of at least
one of the build module, processing chamber, or enclosure may be
controlled by controlling the atmosphere of at least one of the
build module, processing chamber, or enclosure in any combination
or permutation. In some examples, the atmosphere in the build
module is not controllable by controlling the atmosphere in the
processing chamber.
[0150] In some embodiments, the 3D printing system comprises a load
lock. The load lock may be disposed between the processing chamber
and the build module. The load lock may be formed by engaging the
build module with the processing chamber. The load lock may be
sealable. For example, the load lock may be sealed by engaging the
build module with the processing chamber (e.g., directly or
indirectly). In some embodiments, the load lock may comprise one or
more gas opening-ports. At times, the load lock may comprise one or
more gas transport channels. At times, the load lock may comprise
one or more valves. A gas transport channel may comprise a valve.
The opening and/or closing of a first valve of the 3D printing
system may or may not be coordinated with the opening and/or
closing of a second valve of the 3D printing system. The valve may
be controlled automatically (e.g., by a controller) and/or
manually. The load lock may comprise a gas entry opening-port and a
gas exit opening-port. In some embodiments, a pressure below
ambient pressure (e.g., of 1 atmosphere) is formed in the load
lock. In some embodiments, a pressure exceeding ambient pressure
(e.g., of 1 atmosphere) is formed in the load lock. At times,
during the exchange of load lock atmosphere, a pressure below
and/or above ambient pressure if formed in the load lock. At times,
a pressure equal or substantially equal to ambient pressure is
maintained (e.g., automatically and/or manually) in the load lock.
The load lock, building module, processing chamber, and/or
enclosure may comprise a valve. The valve may comprise a pressure
relief, pressure release, pressure safety, safety relief,
pilot-operated relief, low pressure safety, vacuum pressure safety,
low and vacuum pressure safety, pressure vacuum release, snap
acting, or modulating valve. The valve may comply with the legal
industry standards presiding the jurisdiction. The volume of the
load lock may be smaller than the volume within the build module
and/or processing chamber. The total volume within the load lock
may be at most about 0.1%, 0.5%, 1%, 5%, 10%, 20%, 50%, or 80% of
the total volume encompassed by the build module and/or processing
chamber. The total volume within the load lock may be between any
of the afore-mentioned percentage values (e.g., from about 0.1% to
about 80%, from about 0.1% to about 5%, from about 5% to about 20%,
from about 20% to about 50%, or from about 50% to about 80%). The
percentage may be volume per volume percentage.
[0151] In some embodiments, the atmosphere of the build module
and/or the processing chamber is fluidly connected to the
atmosphere of the load lock. At times, conditioning the atmosphere
of the load lock will condition the atmosphere of the build module
and/or the processing chamber that is fluidly connected to the load
lock. The fluid connection may comprise gas flow. The fluid
connection may be through a gas permeable seal and/or through a
channel (e.g., a pipe). The channel may be a sealable channel
(e.g., using a valve).
[0152] In some embodiments, the shutter of the build module engages
with the shutter of the processing chamber. The engagement may be
spatially controlled. For example, when the shutter of the build
module is within a certain gap distance from the processing chamber
shutter, the build module shutter engages with the processing
chamber shutter. The gap distance may trigger an engagement
mechanism. The gap trigger may be sufficient to allow sensing of at
least one of the shutters. The engagement mechanism may comprise
magnetic, electrostatic, electric, hydraulic, pneumatic, or
physical force. The physical force may comprise manual force.
Subsequent to the engagement, the single unit may transfer (e.g.,
relocate, or move) away from the energy beam. For example, the
engagement may trigger the transferring (e.g., relocating) of the
build module shutter and the processing chamber shutter as a single
unit.
[0153] In some examples, removal of the shutter (e.g., of the build
module and/or processing chamber) depends on reaching a certain
(e.g., predetermined) level of at atmospheric characteristics
comprising a gas content (e.g., relative gas content), gas
pressure, oxidizing gas level, humidity, argon level, or nitrogen
level. The atmospheric characteristics may comprise a reactive
agent level. The oxidizing gas may comprise oxygen. The oxidizing
agent may comprise the oxidizing gas. For example, the certain
level may be an equilibrium between an atmospheric characteristic
in the build chamber and that atmospheric characteristics in the
processing chamber.
[0154] In some embodiments, the 3D printing process initiates after
merging of the build module with the processing chamber. At the
beginning of the 3D printing process, the build platform may be at
an elevated position (e.g., FIG. 2, 212). At the end of the 3D
printing process, the build platform may be an a vertically reduced
position (e.g., FIG. 2, 213). The building module may translate
between three positions during a 3D printing run. The build module
may enter to the enclosure from a position away from the engagement
position with the processing chamber (e.g., FIG. 2, 201). The build
module may then advance toward the processing chamber (e.g., FIG.
2, 202), and engage with the processing chamber (e.g., as described
herein). The layer dispensing mechanism and energy beam will
translate and form the 3D object within the material bed (e.g., as
described herein), while the platform gradually lowers its vertical
position. Once the 3D object printing is complete (e.g., FIG. 2,
214), the build module may disengage from the processing chamber
and translate away from the processing chamber engagement position
(e.g., FIG. 2, 203). Disengagement of the build module from the
processing chamber may include closing the processing chamber with
its shutter, closing the build module with its shutter, or both
closing the processing chamber shutter and closing the build module
shutter. Disengagement of the build module from the processing
chamber may include maintaining the processing chamber atmosphere
to be separate from the enclosure atmosphere, maintaining the build
module atmosphere to be separate from the enclosure atmosphere, or
maintaining both the processing chamber atmosphere and the build
atmosphere separate from the enclosure atmosphere. Disengagement of
the build module from the processing chamber may include
maintaining the processing chamber atmosphere to be separate from
the ambient atmosphere, maintaining the build module atmosphere to
be separate from the ambient atmosphere, or maintaining both the
processing chamber atmosphere and the build atmosphere separate
from the ambient atmosphere. The building platform that is disposed
within the build module before engagement with the processing
chamber, may be at its top most position, bottom most position, or
anywhere between its top most position and bottom most position
within the build module.
[0155] In some examples, the usage of sealable build modules,
processing chamber, and/or unpacking chamber allows a small degree
of operator intervention, low degree of operator exposure to the
pre-transformed material, and/or low down time of the 3D printer.
The 3D printing system may operate most of the time without an
intermission. The 3D printing system may be utilized for 3D
printing most of the time. Most of the time may be at least about
50%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, or 99% of the time. Most of
the time may be between any of the afore-mentioned values (e.g.,
from about 50% to about 99%, from about 80% to about 99%, from
about 90% to about 99%, or from about 95% to about 99% of the time.
The entire time includes the time during which the 3D printing
system prints a 3D object, and time during which it does not print
a 3D object. Most of the time may include operation during seven
days a week and/or 24 hours during a day.
[0156] In some embodiments, the processing chamber (e.g., FIG. 8,
826) comprises one or more side walls (e.g., 873). The processing
chamber may comprise at least one inlet (e.g., FIG. 8, 844, 846)
coupled to a first of the processing chamber side walls. The
processing chamber may comprise at least one outlet (e.g., FIG. 8,
872) coupled to a side wall of the chamber. The side wall that is
connected to the inlet may not be connected to the outlet. The side
wall connected to the inlet may be different from the side wall
connected to the outlet. For example, the inlet may be coupled to
the first of the processing chamber side walls, and the outlet may
be coupled to the second of the processing chamber side walls. The
first side wall may be different from the second side wall. For
example, the first side wall may oppose the second side wall. The
outlet opening may be (e.g., fluidly) connected to a gas recycling
system. In some embodiments, the outlet opening (or a supplemental
outlet opening) may be adjacent to an optical window. The outlet
opening may be (e.g., fluidly) connected to a pump. Fluid
connection may allow a gas to flow through. The gas may flow
through the opening due to a pressure difference between the two
sides of the outlet opening. The gas may be sucked through the
outlet opening. The gas may be pressurized through the outlet
opening. The pressure at the side of the opening away from the
processing pressure may be lower than the pressure at the side of
the outlet opening closer to the processing chamber. At times, the
pressure at the two sides of the outlet opening may be (e.g.,
substantially) equal.
[0157] In some embodiments, the temperature of the gas that flows
to the processing chamber and/or processing cone may be temperature
controlled. For example, the gas may be heated and/or cooled
before, or during the time it flows into the processing chamber
and/or cone. For example, the gas may flow through a heat exchanger
and/or heat sink. The gas may be temperature controlled outside
and/or inside the processing chamber. The gas may be temperature
controlled at least one inlet to the processing chamber. In some
embodiments, the temperature of the atmosphere in the processing
chamber and/or cone may be kept (e.g., substantially) constant.
Substantially constant temperature may allow for a temperature
fluctuation (e.g., error delta) of at most about 15.degree. C.,
12.degree. C., 10.degree. C., 5.degree. C., 4.degree. C., 3.degree.
C., 2.degree. C., 1.degree. C., or 0.5.degree. C.
[0158] In some examples, the 3D printing system requires operation
of maximum a single standard daily work shift. The 3D printing
system may require operation by a human operator working at most of
about 8 hours (h), 7 h, 6 h, 5 h, 4 h, 3 h, 2 h, 1 h, or 0.5 h a
day. The 3D printing system may require operation by a human
operator working between any of the afore-mentioned time frames
(e.g., from about 8 h to about 0.5 h, from about 8 h to about 4 h,
from about 6 h to about 3 h, from about 3 h to about 0.5 h, or from
about 2 h to about 0.5 h a day).
[0159] In some examples, the 3D printing system requires operation
of maximum a single standard work week shift. The 3D printing
system may require operation by a human operator working at most of
about 50 h, 40 h, 30 h, 20 h, 10 h, 5 h, or 1 h a week. The 3D
printing system may require operation by a human operator working
between any of the afore-mentioned time frames (e.g., from about 40
h to about 1 h, from about 40 h to about 20 h, from about 30 h to
about 10 h, from about 20 h to about 1 h, or from about 10 h to
about 1 h a week). A single operator may support during his daily
and/or weekly shift at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 3D
printers (i.e., 3D printing systems).
[0160] In some embodiments, the enclosure and/or processing chamber
of the 3D printing system may be opened to the ambient environment
sparingly. In some embodiments, the enclosure and/or processing
chamber of the 3D printing system may be opened by an operator
(e.g., human) sparingly. Sparing opening may be at most once in at
most every 1, 2, 3, 4, or 5 weeks. The weeks may comprise weeks of
standard operation of the 3D printer.
[0161] In some embodiments, the 3D printer has a capacity of 1, 2,
3, 4, or 5 full prints in terms of pre-transformed material (e.g.,
powder) reservoir capacity. The 3D printer may have the capacity to
print a plurality of 3D objects in parallel. For example, the 3D
printer may be able to print at least 2, 3, 4, 5, 6, 7, 8, 9, or 10
3D objects in parallel.
[0162] In some embodiments, the printed 3D object is retrieved soon
after terminating the last transformation operation of at least a
portion of the material bed. Soon after terminating may be at most
about 1 day, 12 hours, 6 hours, 3 hours, 2 hours, 1 hour, 30
minutes, 15 minutes, 5 minutes, 240 seconds (sec), 220 sec, 200
sec, 180 sec, 160 sec, 140 sec, 120 sec, 100 sec, 80 sec, 60 sec,
40 sec, 20 sec, 10 sec, 9 sec, 8 sec, 7 sec, 6 sec, 5 sec, 4 sec, 3
sec, 2 sec, or 1 sec. Soon after terminating may be between any of
the afore-mentioned time values (e.g., from about is to about 1
day, from about is to about 1 hour, from about 30 minutes to about
1 day, or from about 20 s to about 240 s).
[0163] In some embodiments, the 3D printer has a capacity of 1, 2,
3, 4, or 5 full prints before requiring human intervention. Human
intervention may be required for refilling the pre-transformed
(e.g., powder) material, unloading the build modules, unpacking the
3D object, or any combination thereof. The 3D printer operator may
condition the 3D printer at any time during operation of the 3D
printing system (e.g., during the 3D printing process).
Conditioning of the 3D printer may comprise refilling the
pre-transformed material that is used by the 3D printer, replacing
gas source, or replacing filters. The conditioning may be with or
without interrupting the 3D printing system. For example, refilling
and unloading from the 3D printer can be done at any time during
the 3D printing process without interrupting the 3D printing
process. Conditioning may comprise refreshing the 3D printer.
[0164] In some embodiments, the 3D printer comprises a filter. The
3D printer may comprise at least one filter. The filter may be a
ventilation filter. The ventilation filter may capture fine powder
from the 3D printing system. The filter may comprise a paper filter
such as a high-efficiency particulate arrestance (TEPA) filter
(a.k.a., high-efficiency particulate arresting or high-efficiency
particulate air filter). The ventilation filter may capture
spatter. The spatter may result from the 3D printing process. The
ventilator may direct the spatter in a desired direction (e.g., by
using positive or negative gas pressure). For example, the
ventilator may use vacuum. For example, the ventilator may use gas
blow.
[0165] In some embodiments, there is a time lapse between the end
of a first 3D printing cycle in a first material bed and the
beginning of a second 3D printing cycle in a second material bed.
The time lapse between the end of the first 3D printing cycle in a
first material bed, and the beginning of the second 3D printing
cycle in a second material bed may be at most about 60 minutes
(min), 40 min, 30 min, 20 min, 15 min, 10 min, or 5 min. The time
lapse between the end of printing in a first material bed, and the
beginning of printing in a second material bed may be between any
of the afore-mentioned times (e.g., from about 60 min to abo 5 min,
from about 60 min to about 30 min, from about 30 min to about 5
min, from about 20 min to about 5 min, from about 20 min to about
10 min, or from about 15 min to about 5 min). The speed during
which the 3D printing process proceeds is disclosed in Patent
Application serial number PCT/US15/36802 that is incorporated
herein in its entirety.
[0166] In some embodiments, the generated 3D object requires very
little or no further processing after its retrieval. Further
processing may be post printing processing. Further processing may
comprise trimming, as disclosed herein. Further processing may
comprise polishing (e.g., sanding). In some cases, the generated 3D
object can be retrieved and finalized without removal of
transformed material and/or auxiliary support features.
[0167] In some embodiments, the 3D object (e.g., solidified
material) that is generated has an average deviation value from the
intended dimensions (e.g., of a desired 3D object) of at most about
0.5 microns (.mu.m), 1 .mu.m, 3 .mu.m, 10 .mu.m, 30 .mu.m, 100
.mu.m, 300 .mu.m or less. The deviation can be any value between
the afore-mentioned values. The average deviation can be from about
0.5 .mu.m to about 300 .mu.m, from about 10 .mu.m to about 50
.mu.m, from about 15 .mu.m to about 85 .mu.m, from about 5 .mu.m to
about 45 .mu.m, or from about 15 .mu.m to about 35 .mu.m. The 3D
object can have a deviation from the intended dimensions in a
specific direction, according to the formula Dv+L/K.sub.dv, wherein
Dv is a deviation value, L is the length of the 3D object in a
specific direction, and K.sub.dv is a constant. Dv can have a value
of at most about 300 .mu.m, 200 .mu.m, 100 .mu.m, 50 .mu.m, 40
.mu.m, 30 .mu.m, 20 .mu.m, 10 .mu.m, 5 .mu.m, 1 .mu.m, or 0.5
.mu.m. Dv can have a value of at least about 0.5 .mu.m, 1 .mu.m, 3
.mu.m, 5 .mu.m, 10 .mu.m, 20 .mu.m, 30 .mu.m, 50 .mu.m, 70 .mu.m,
100 .mu.m, 300 .mu.m or less. Dv can have any value between the
afore-mentioned values. For example, Dv can have a value that is
from about 0.5 .mu.m to about 300 .mu.m, from about 10 .mu.m to
about 50 .mu.m, from about 15 .mu.m to about 85 .mu.m, from about 5
.mu.m to about 45 .mu.m, or from about 15 .mu.m to about 35 .mu.m.
K.sub.dv can have a value of at most about 3000, 2500, 2000, 1500,
1000, or 500. K.sub.dv can have a value of at least about 500,
1000, 1500, 2000, 2500, or 3000. K.sub.dv can have any value
between the afore-mentioned values. For example, K.sub.dv can have
a value that is from about 3000 to about 500, from about 1000 to
about 2500, from about 500 to about 2000, from about 1000 to about
3000, or from about 1000 to about 2500.
[0168] In some examples, the generated 3D object requires a
diminished amount of further processing. The generated 3D object
(i.e., the printed 3D object) may not require further processing
following its generation by a method described herein. The printed
3D object may require reduced amount of processing after its
generation by a method described herein. For example, the printed
3D object may not require removal of auxiliary support (e.g., since
the printed 3D object was generated as a 3D object devoid of
auxiliary support). The printed 3D object may not require
smoothing, flattening, polishing, or leveling. The printed 3D
object may not require further machining. In some examples, the
printed 3D object may require one or more treatment operations
following its generation (e.g., post generation treatment, or post
printing treatment). The further treatment step(s) may comprise
surface scraping, machining, polishing, grinding, blasting (e.g.,
sand blasting, bead blasting, shot blasting, or dry ice blasting),
annealing, or chemical treatment. The further treatment may
comprise physical or chemical treatment. The further treatment
step(s) may comprise electrochemical treatment, ablating, polishing
(e.g., electro polishing), pickling, grinding, honing, or lapping.
In some examples, the printed 3D object may require a single
operation (e.g., of sand blasting) following its formation. The
printed 3D object may require an operation of sand blasting
following its formation. Polishing may comprise electro polishing
(e.g., electrochemical polishing or electrolytic polishing). The
further treatment may comprise the use of abrasive(s). The blasting
may comprise sand blasting or soda blasting. The chemical treatment
may comprise use or an agent. The agent may comprise an acid, a
base, or an organic compound. The further treatment step(s) may
comprise adding at least one added layer (e.g., cover layer). The
added layer may comprise lamination. The added layer may be of an
organic or inorganic material. The added layer may comprise
elemental metal, metal alloy, ceramic, or elemental carbon. The
added layer may comprise at least one material that composes the
printed 3D object. When the printed 3D object undergoes further
treatment, the bottom most surface layer of the treated object may
be different than the original bottom most surface layer that was
formed by the 3D printing (e.g., the bottom skin layer).
[0169] The methods described herein can be performed in the
enclosure (e.g., container, processing chamber, and/or build
module). One or more 3D objects can be formed in the enclosure
(e.g., simultaneously and/or sequentially). The enclosure may have
a predetermined and/or controlled pressure. The enclosure may have
a predetermined and/or controlled atmosphere. The control may be
manual or via a control system. The atmosphere may comprise at
least one gas.
[0170] In some embodiments, the enclosure comprises a gas pressure.
The enclosure may comprise ambient pressure (e.g., 1 atmosphere),
negative pressure (i.e., vacuum) or positive pressure. Different
portions of the enclosure may have different atmospheres. The
different atmospheres may comprise different gas compositions. The
different atmospheres may comprise different atmosphere
temperatures. The different atmospheres may comprise ambient
pressure (e.g., 1 atmosphere), negative pressure (i.e., vacuum) or
positive pressure. The different portions of the enclosure may
comprise the processing chamber, build module, or enclosure volume
excluding the processing chamber and/or build module. The vacuum
may comprise pressure below 1 bar, or below 1 atmosphere. The
positively pressurized environment may comprise pressure above 1
bar or above 1 atmosphere. The pressure in the enclosure can be at
least about 10.sup.-7 Torr, 10.sup.-6 Torr, 10.sup.-5 Torr,
10.sup.-4 Torr, 10.sup.-3 Torr, 10.sup.-2 Torr, 10.sup.-1 Torr, 1
Torr, 10 Torr, 100 Torr, 1 bar, 2 bar, 3 bar, 4 bar, 5 bar, 10 bar,
20 bar, 30 bar, 40 bar, 50 bar, 100 bar, 200 bar, 300 bar, 400 bar,
500 bar, 1000 bar, or 1100 bar. The pressure in the enclosure can
be at least about 100 Torr, 200 Torr, 300 Torr, 400 Torr, 500 Torr,
600 Torr, 700 Torr, 720 Torr, 740 Torr, 750 Torr, 760 Torr, 900
Torr, 1000 Torr, 1100 Torr, or 1200 Ton. The pressure in the
enclosure can be between any of the afore-mentioned enclosure
pressure values (e.g., from about 10.sup.-7 Torr to about 1200
Torr, from about 10.sup.-7 Ton to about 1 Torr, from about 1 Torr
to about 1200 Torr, or from about 10.sup.-3 Torr to about 10 Torr).
The chamber can be pressurized to a pressure of at least 10.sup.-7
Torr, 10.sup.-6 Torr, 10.sup.-5 Torr, 10.sup.-4 Torr, 10.sup.-3
Torr, 10.sup.-2 Torr, 10.sup.-1 Torr, 1 Torr, 10 Torr, 100 Torr, 1
bar, 2 bar, 3 bar, 4 bar, 5 bar, 10 bar, 20 bar, 30 bar, 40 bar, 50
bar, 100 bar, 200 bar, 300 bar, 400 bar, 500 bar, or 1000 bar. The
chamber can be pressurized to a pressure of at most 10.sup.-7 Torr,
10.sup.-6 Torr, 10.sup.-5 Torr, 10.sup.-4 Torr, 10.sup.-3 Torr,
10.sup.-2 Torr, 10.sup.-1 Torr, 1 Torr, 10 Torr, 100 Torr, 1 bar, 2
bar, 3 bar, 4 bar, 5 bar, 10 bar, 20 bar, 30 bar, 40 bar, 50 bar,
100 bar, 200 bar, 300 bar, 400 bar, 500 bar, or 1000 bar. The
pressure in the chamber can be at a range between any of the
afore-mentioned pressure values (e.g., from about 10.sup.-7 Torr to
about 1000 bar, from about 10.sup.-7 Ton to about 1 Torr, from
about 1 Torr to about 100 Barr, from about 1 bar to about 10 bar,
from about 1 bar to about 100 bar, or from about 100 bar to about
1000 bar). In some cases, the chamber pressure can be standard
atmospheric pressure. The pressure may be measured at an ambient
temperature (e.g., room temperature, 20.degree. C., or 25.degree.
C.).
[0171] In some embodiments, the enclosure includes an atmosphere
comprising at least one gas. The enclosure may comprise a (e.g.,
substantially) inert atmosphere. The atmosphere in the enclosure
may be (e.g., substantially) depleted by one or more gases present
in the ambient atmosphere. The atmosphere in the enclosure may
include a reduced level of one or more gases relative to the
ambient atmosphere. For example, the atmosphere may be
substantially depleted, or have reduced levels of water (i.e.,
humidity), oxidizing gas (e.g., oxygen), nitrogen, carbon dioxide,
hydrogen sulfide, or any combination thereof. For example, the
atmosphere may be substantially depleted, or have reduced levels of
a reactive agent. The level of the depleted or reduced level may be
at most about 1 ppm, 10 ppm, 50 ppm, 100 ppm, 500 ppm, 1000 ppm,
5000 ppm, 10000 ppm, 25000 ppm, 50000 ppm, or 70000 ppm volume by
volume (v/v). The level of the depleted or reduced level may be at
least about 1 ppm, 10 ppm, 50 ppm, 100 ppm, 500 ppm, 1000 ppm, 5000
ppm, 10000 ppm, 25000 ppm, 50000 ppm, or 70000 ppm (v/v). The level
(e.g., depleted or reduced level gas, oxidizing gas, or water) may
between any of the afore-mentioned levels. The atmosphere may
comprise air. The atmosphere may be inert. The atmosphere may be
non-reactive. The atmosphere may be non-reactive with the material
(e.g., the pre-transformed material deposited in the layer of
material (e.g., powder), or the material comprising the 3D object).
The atmosphere may prevent oxidation of the generated 3D object.
The atmosphere may prevent oxidation of the pre-transformed
material within the layer of pre-transformed material before its
transformation, during its transformation, after its
transformation, before its hardening, after its hardening, or any
combination thereof. The atmosphere may comprise argon or nitrogen
gas. The atmosphere may comprise a Nobel gas. The atmosphere can
comprise a gas selected from the group consisting of argon,
nitrogen, helium, neon, krypton, xenon, hydrogen, carbon monoxide,
and carbon dioxide. The atmosphere may comprise hydrogen gas. The
atmosphere may comprise a safe amount of hydrogen gas. The
atmosphere may comprise a v/v percent of hydrogen gas of at least
about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%,
1%, 2%, 3%, 4%, or 5%, at ambient pressure (e.g., and ambient
temperature). The atmosphere may comprise a v/v percent of hydrogen
gas of at most about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%,
0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, or 5%, at ambient pressure (e.g.,
and ambient temperature). The atmosphere may comprise any percent
of hydrogen between the afore-mentioned percentages of hydrogen
gas. The atmosphere may comprise a v/v hydrogen gas percent that is
at least able to react with the material (e.g., at ambient
temperature and/or at ambient pressure), and at most adhere to the
prevalent work-safety standards in the jurisdiction (e.g., hydrogen
codes and standards). The material may be the material within the
layer of pre-transformed material (e.g., powder), the transformed
material, the hardened material, or the material within the 3D
object. Ambient refers to a condition to which people are generally
accustomed. For example, ambient pressure may be 1 atmosphere.
Ambient temperature may be a typical temperature to which humans
are generally accustomed. For example, from about 15.degree. C. to
about 30.degree. C., from about -30.degree. C. to about 60.degree.
C., from about -20.degree. C. to about 50.degree. C., from
16.degree. C. to about 26.degree. C., from about 20.degree. C. to
about 25.degree. C. "Room temperature" may be measured in a
confined or in a non-confined space. For example, "room
temperature" can be measured in a room, an office, a factory, a
vehicle, a container, or outdoors. The vehicle may be a car, a
truck, a bus, an airplane, a space shuttle, a space ship, a ship, a
boat, or any other vehicle. Room temperature may represent the
small range of temperatures at which the atmosphere feels neither
hot nor cold, approximately 24.degree. C. it may denote 20.degree.
C., 25.degree. C., or any value from about 20.degree. C. to about
25.degree. C.
[0172] In some embodiments, the pre-transformed material is
deposited in an enclosure (e.g., a container). FIG. 1 shows an
example of a container 123. The container can contain the
pre-transformed material (e.g., without spillage; FIG. 1, 104). The
material may be placed in, or inserted to the container. The
material may be deposited in, pushed to, sucked into, or lifted to
the container. The material may be layered (e.g., spread) in the
container. The container may comprise a substrate (e.g., FIG. 1,
109). The substrate may be situated adjacent to the bottom of the
container (e.g., FIG. 1, 111). Bottom may be relative to the
gravitational field, or relative to the position of the footprint
of the energy beam (e.g., FIG. 1, 101) on the layer of
pre-transformed material as part of a material bed. The footprint
of the energy beam may follow a Gaussian bell shape. In some
embodiments, the footprint of the energy beam does not follow a
Gaussian bell shape. The container may comprise a platform
comprising a base (e.g., FIG. 1, 102). The platform may comprise a
substrate. The base may reside adjacent to the substrate. The
pre-transformed material may be layered adjacent to a side of the
container (e.g., on the bottom of the container). The
pre-transformed material may be layered adjacent to the substrate
and/or adjacent to the base. Adjacent to may be above. Adjacent to
may be directly above, or directly on. The substrate may have one
or more seals that enclose the material in a selected area within
the container (e.g., FIG. 1, 103). The one or more seals may be
flexible or non-flexible. The one or more seals may comprise a
polymer or a resin. The one or more seals may comprise a round edge
or a flat edge. The one or more seals may be bendable or
non-bendable. The seals may be stiff. The container may comprise
the base. The base may be situated within the container. The
container may comprise the platform, which may be situated within
the container. The enclosure, container, processing chamber, and/or
building module may comprise an optical window or an optical
mechanism (e.g., FIG. 1, 120). An example of an optical window can
be seen in FIG. 1, 115; and FIG. 3, 304. The optical window may
allow the energy beam (e.g., 307) to pass through without (e.g.,
substantial) energetic loss (e.g., 303). A ventilator may prevent
spatter from accumulating on the surface optical window that is
disposed within the enclosure (e.g., within the processing chamber)
during the 3D printing. An opening of the ventilator may be
situated within the enclosure 116. A portion of the enclosure, that
is occupied by the energy beam (e.g., during the 3D printing) can
define a processing cone (e.g., FIG. 15, 1530). During the 3D
printing may comprise during the entire 3D printing. The processing
cone can be the enclosure space that is occupied by a non-reflected
energy beam during the (e.g., entire) 3D printing. The processing
cone can be the enclosure space that is occupied by an energy beam
that is directed towards the material bed during the (e.g., entire)
3D printing. During the 3D printing may comprise during printing of
a layer of hardened material.
[0173] In some embodiments, the 3D printer comprises a material
dispensing mechanism. The pre-transformed material may be deposited
in the enclosure by a material dispensing mechanism (also referred
to herein as a layer dispenser, layer forming apparatus, or layer
forming device) (e.g., FIG. 1, 122). In some embodiments, the
material dispensing mechanism includes one or more material
dispensers (also referred to herein as "dispensers") (e.g., FIG. 1,
116), one or more leveling mechanisms (also referred to herein as
"levelers") (e.g., FIG. 1, 117), and/or one or more powder removal
mechanisms (also referred to herein as material "removers") (e.g.,
FIG. 1, 118) to form a layer of pre-transformed material within the
enclosure. The deposited material may be leveled by a leveling
operation. The leveling operation may comprise using a powder
removal mechanism that does not contact the exposed surface of the
material bed (e.g., FIG. 1, 118). The leveling operation may
comprise using a leveling mechanism that contacts the exposed
surface of the material bed (e.g., FIG. 1, 117). The material
(e.g., powder) dispensing mechanism may comprise one or more
dispensers (e.g., FIG. 1, 116). The material dispensing system may
comprise at least one material (e.g., bulk) reservoir. The material
may be deposited by a layer dispensing mechanism (e.g., recoater).
The layer dispensing mechanism may level the dispensed material
without contacting the material bed (e.g., the top surface of the
powder bed). The layer dispensing mechanism may include any layer
dispensing mechanism and/or a material (e.g., powder) dispenser
used in 3D printing such as, for example, the ones disclosed in
international patent application number PCT/US15/36802 titled
"APPARATUSES, SYSTEMS AND METHODS FOR 3D PRINTING" that was filed
on Jun. 19, 2015, in international patent application number
PCT/US16/66000 that was filed on Dec. 9, 2016, titled "SKILLFUL
THREE-DIMENSIONAL PRINTING," or international patent application
number PCT/US17/57340 that was filed on Oct. 19, 2017, titled
"OPERATION OF THREE-DIMENSIONAL PRINTER COMPONENTS," each of which
is entirely incorporated herein by reference. The FLS (e.g., width,
depth, and/or height) of the material bed can be at least about 50
millimeters (mm), 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 250
mm, 280 mm, 400 mm, 500 mm, 600 mm, 800 mm, 900 mm, 1 meter (m), 2
m or 5 m. The FLS (e.g., width, depth, and/or height) of the
material bed can be at most about 50 millimeters (mm), 60 mm, 70
mm, 80 mm, 90 mm, 100 mm, 200 mm, 250 mm, 280 mm, 400 mm, 500 mm,
600 mm, 800 mm, 900 mm, 1 meter (m), 2 m or 5 m. The FLS of the
material bed can be between any of the afore-mentioned values
(e.g., from about 50 mm to about 5 m, from about 250 mm to about
500 mm, from about 280 mm to about 1 m, or from about 500 mm to
about 5 m). In some embodiments, the FLS of the material bed is in
the direction of the gas flow. The layer dispensing mechanism may
include components comprising a material dispensing mechanism,
material leveling mechanism, material removal mechanism, or any
combination or permutation thereof. The layer dispensing mechanism
and any of its components may be any layer dispensing mechanism
(e.g., used in 3D printing) such as for example, any of the ones
described in Patent Application serial number PCT/US15/36802, or in
Provisional Patent Application Ser. No. 62/317,070, both of which
are entirely incorporated herein by references.
[0174] In some embodiments, the layer dispensing mechanism may
reside within an ancillary chamber. The ancillary chamber may be
any ancillary chamber such as, for example, the one described in
Provisional Patent Application Ser. No. 62/471,222 filed Mar. 14,
2017, titled "OPERATION OF THREE-DIMENSIONAL PRINTER COMPONENTS",
which is entirely incorporated herein by reference in its entirety.
The layer dispenser may be physically secluded from the processing
chamber when residing in the ancillary chamber. The ancillary
chamber may be connected (e.g., reversibly) to the processing
chamber. The ancillary chamber may be connected (e.g., reversibly)
to the build module. The ancillary chamber may convey the layer
dispensing mechanism adjacent to a platform (e.g., that is disposed
within the build module). The layer dispensing mechanism may be
retracted into the ancillary chamber (e.g., when the layer
dispensing mechanism does not perform dispensing).
[0175] In some embodiments, the 3D printer comprises a platform.
The platform (also herein, "printing platform" or "building
platform") may be disposed in the enclosure (e.g., in the build
module and/or processing chamber). The platform may be configured
to support the material bed. The platform may be configured to
support multiple layers of pre-transformed material (e.g., as part
of the material bed). The platform may be configured to support at
least a portion of the 3D object (e.g., during forming of the 3D
object). The platform may comprise a substrate or a base. The
substrate and/or the base may be removable or non-removable. The
building platform may be (e.g., substantially) horizontal, (e.g.,
substantially) planar, or non-planar. The platform may have a
surface that points towards the deposited pre-transformed material
(e.g., powder material), which at times may point towards the top
of the enclosure (e.g., away from the center of gravity). The
platform may have a surface that points away from the deposited
pre-transformed material (e.g., towards the center of gravity),
which at times may point towards the bottom of the container. The
platform may have a surface that is (e.g., substantially) flat
and/or planar. The platform may have a surface that is not flat
and/or not planar. The platform may have a surface that comprises
protrusions or indentations. The platform may have a surface that
comprises embossing. The platform may have a surface that comprises
supporting features (e.g., auxiliary support). The platform may
have a surface that comprises a mold. The platform may have a
surface that comprises a wave formation. The surface may point
towards the layer of pre-transformed material within the material
bed. The wave may have an amplitude (e.g., vertical amplitude or at
an angle). The platform (e.g., base) may comprise a mesh through
which the pre-transformed material (e.g., the remainder) is able to
flow through. The platform may comprise a motor. The platform
(e.g., substrate and/or base) may be fastened to the container. The
platform (or any of its components) may be transportable. The
transportation of the platform may be controlled and/or regulated
by a controller (e.g., control system). The platform may be
transportable horizontally, vertically, or at an angle (e.g.,
planar or compound).
[0176] In some embodiments, the platform is transferable (e.g.,
translatable). The platform may be vertically transferable, for
example using an actuator. The actuator may cause a vertical
translation (e.g., and elevator). An actuator causing a vertical
translation (e.g., an elevation mechanism) is shown as an example
in FIG. 1, 105. The up and down arrow next to the elevation
mechanism 105 signifies a possible direction of movement of the
elevation mechanism, or a possible direction of movement
effectuated by the elevation mechanism.
[0177] In some examples, auxiliary support(s) adhere to the upper
surface of the platform. In some examples, the auxiliary supports
of the printed 3D object may touch the platform (e.g., the bottom
of the enclosure, the substrate, or the base). Sometimes, the
auxiliary support may adhere to the platform. In some embodiments,
the auxiliary supports are an integral part of the platform. At
times, auxiliary support(s) of the printed 3D object, do not touch
the platform. In any of the methods described herein, the printed
3D object may be supported only by the pre-transformed material
within the material bed (e.g., powder bed, FIG. 1, 104). Any
auxiliary support(s) of the printed 3D object, if present, may be
suspended adjacent to the platform. Occasionally, the platform may
have a pre-hardened (e.g., pre-solidified) amount of material. Such
pre-solidified material may provide support to the printed 3D
object. At times, the platform may provide adherence to the
material. At times, the platform does not provide adherence to the
material. The platform may comprise elemental metal, metal alloy,
elemental carbon, or ceramic. The platform may comprise a composite
material (e.g., as disclosed herein). The platform may comprise
glass, stone, zeolite, or a polymeric material. The polymeric
material may include a hydrocarbon or fluorocarbon. The platform
(e.g., base) may include Teflon. The platform may include
compartments for printing small objects. Small may be relative to
the size of the enclosure. The compartments may form a smaller
compartment within the enclosure, which may accommodate a layer of
pre-transformed material.
[0178] In some embodiments, the 3D printer comprises an energy
source that generates an energy beam. The energy beam may project
energy to the material bed. The apparatuses, systems, and/or
methods described herein can comprise at least one energy beam. In
some cases, the apparatuses, systems, and/or methods described can
comprise two, three, four, five, or more energy beams. The energy
beam may include radiation comprising electromagnetic, electron,
positron, proton, plasma, or ionic radiation. The electromagnetic
beam may comprise microwave, infrared, ultraviolet or visible
radiation. The ion beam may include a cation or an anion. The
electromagnetic beam may comprise a laser beam. The energy beam may
derive from a laser source. The energy source (e.g., FIG. 1, 121)
may be a laser source. The laser may comprise a fiber laser, a
solid-state laser or a diode laser.
[0179] In some embodiments, the energy source is a laser source.
The laser source may comprise a Nd: YAG, Neodymium (e.g.,
neodymium-glass), or an Ytterbium laser. The laser may comprise a
carbon dioxide laser (CO.sub.2 laser). The laser may be a fiber
laser. The laser may be a solid-state laser. The laser can be a
diode laser. The energy source may comprise a diode array. The
energy source may comprise a diode array laser. The laser may be a
laser used for micro laser sintering. The energy beam may be any
energy beam disclosed in Provisional Patent Application Ser. No.
62/317,070 that is entirely incorporated herein by reference.
[0180] In some embodiments, the energy beam (e.g., transforming
energy beam) comprises a Gaussian energy beam. The energy beam may
have any cross-sectional shape comprising an ellipse (e.g.,
circle), or a polygon (e.g., as disclosed herein). The energy beam
may have a cross section with a FLS (e.g., diameter) of at least
about 50 micrometers (.mu.m), 100 .mu.m, 150 .mu.m, 200 .mu.m, or
250 .mu.m. The energy beam may have a cross section with a FLS of
at most about 60 micrometers (.mu.m), 100 .mu.m, 150 .mu.m, 200
.mu.m, or 250 .mu.m. The energy beam cross section may be measured
at full width half maximum. The energy beam may have a cross
section with a FLS of any value between the afore-mentioned values
(e.g., from about 50 .mu.m to about 250 .mu.m, from about 50 .mu.m
to about 150 .mu.m, or from about 150 .mu.m to about 250 .mu.m).
The power per unit area of the energy beam may be at least about
100 Watt per millimeter square (W/mm.sup.2), 200 W/mm.sup.2, 300
W/mm.sup.2, 400 W/mm.sup.2, 500 W/mm.sup.2, 600 W/mm.sup.2, 700
W/mm.sup.2, 800 W/mm.sup.2, 900 W/mm.sup.2, 1000 W/mm.sup.2, 2000
W/mm.sup.2, 3000 W/mm.sup.2, 5000 W/mm2, 7000 W/mm.sup.2, or 10000
W/mm.sup.2. The power per unit area of the tiling energy flux may
be at most about 110 W/mm.sup.2, 200 W/mm.sup.2, 300 W/mm.sup.2,
400 W/mm.sup.2, 500 W/mm.sup.2, 600 W/mm.sup.2, 700 W/mm.sup.2, 800
W/mm.sup.2, 900 W/mm.sup.2, 1000 W/mm.sup.2, 2000 W/mm.sup.2, 3000
W/mm.sup.2, 5000 W/mm.sup.2, 7000 W/mm.sup.2, or 10000 W/mm.sup.2.
The power per unit area of the energy beam may be any value between
the afore-mentioned values (e.g., from about 100 W/mm.sup.2 to
about 3000 W/mm.sup.2, from about 100 W/mm.sup.2 to about 5000
W/mm.sup.2, from about 100 W/mm.sup.2 to about 10000 W/mm.sup.2,
from about 100 W/mm.sup.2 to about 500 W/mm.sup.2, from about 1000
W/mm.sup.2 to about 3000 W/mm.sup.2, from about 1000 W/mm.sup.2 to
about 3000 W/mm.sup.2, or from about 500 W/mm.sup.2 to about 1000
W/mm.sup.2). The scanning speed of the energy beam may be at least
about 50 millimeters per second (mm/sec), 100 mm/sec, 500 mm/sec,
1000 mm/sec, 2000 mm/sec, 3000 mm/sec, 4000 mm/sec, or 50000
mm/sec. The scanning speed of the energy beam may be at most about
50 mm/sec, 100 mm/sec, 500 mm/sec, 1000 mm/sec, 2000 mm/sec, 3000
mm/sec, 4000 mm/sec, or 50000 mm/sec. The scanning speed of the
energy beam may any value between the afore-mentioned values (e.g.,
from about 50 mm/sec to about 50000 mm/sec, from about 50 mm/sec to
about 3000 mm/sec, or from about 2000 mm/sec to about 50000
mm/sec). The energy beam may be continuous or non-continuous (e.g.,
pulsing). The energy beam may be modulated before and/or during the
formation of a transformed material as part of the 3D object. The
energy beam may be modulated before and/or during the 3D printing
process.
[0181] In some embodiments, the energy source (e.g., laser) has a
power of at least about 10 Watt (W), 30 W, 50 W, 80 W, 100 W, 120
W, 150 W, 200 W, 250 W, 300 W, 350 W, 400 W, 500 W, 750 W, 800 W,
900 W, 1000 W, 1500 W, 2000 W, 3000 W, or 4000 W. The energy source
may have a power of at most about 10 W, 30 W, 50 W, 80 W, 100 W,
120 W, 150 W, 200 W, 250 W, 300 W, 350 W, 400 W, 500 W, 750 W, 800
W, 900 W, 1000 W, 1500, 2000 W, 3000 W, or 4000 W. The energy
source may have a power between any of the afore-mentioned energy
beam power values (e.g., from about 10 W to about 100 W, from about
100 W to about 1000 W, or from about 1000 W to about 4000 W). The
energy beam may derive from an electron gun. The energy beam may
include a pulsed energy beam, a continuous wave energy beam, or a
quasi-continuous wave energy beam. The pulse energy beam may have a
repetition frequency of at least about 1 Kilo Hertz (KHz), 2 KHz, 3
KHz, 4 KHz, 5 KHz, 6 KHz, 7 KHz, 8 KHz, 9 KHz, 10 KHz, 20 KHz, 30
KHz, 40 KHz, 50 KHz, 60 KHz, 70 KHz, 80 KHz, 90 KHz, 100 KHz, 150
KHz, 200 KHz, 250 KHz, 300 KHz, 350 KHz, 400 KHz, 450 KHz, 500 KHz,
550 KHz, 600 KHz, 700 KHz, 800 KHz, 900 KHz, 1 Mega Hertz (MHz), 2
MHz, 3 MHz, 4 MHz, or 5 MHz. The pulse energy beam may have a
repetition frequency of at most about 1 Kilo Hertz (KHz), 2 KHz, 3
KHz, 4 KHz, 5 KHz, 6 KHz, 7 KHz, 8 KHz, 9 KHz, 10 KHz, 20 KHz, 30
KHz, 40 KHz, 50 KHz, 60 KHz, 70 KHz, 80 KHz, 90 KHz, 100 KHz, 150
KHz, 200 KHz, 250 KHz, 300 KHz, 350 KHz, 400 KHz, 450 KHz, 500 KHz,
550 KHz, 600 KHz, 700 KHz, 800 KHz, 900 KHz, 1 Mega Hertz (MHz), 2
MHz, 3 MHz, 4 MHz, or 5 MHz. The pulse energy beam may have a
repetition frequency between any of the afore-mentioned repetition
frequencies (e.g., from about 1 KHz to about 5 MHz, from about 1
KHz to about 1 MHz, or from about 1 MHz to about 5 MHz).
[0182] The methods, apparatuses and/or systems disclosed herein may
comprise Q-switching, mode coupling or mode locking to effectuate
the pulsing energy beam. The apparatus or systems disclosed herein
may comprise an on/off switch, a modulator, or a chopper to
effectuate the pulsing energy beam. The on/off switch can be
manually or automatically controlled. The switch may be controlled
by the control system. The switch may alter the "pumping power" of
the energy beam. The energy beam may be at times focused,
non-focused, or defocused. In some instances, the defocus is
substantially zero (e.g., the beam is non-focused).
[0183] In some embodiments, the energy source(s) projects energy
using a DLP modulator, a one-dimensional scanner, a two-dimensional
scanner, or any combination thereof. The energy source(s) can be
stationary or translatable. The energy source(s) can translate
vertically, horizontally, or in an angle (e.g., planar or compound
angle). The energy source(s) can be modulated. The energy beam(s)
emitted by the energy source(s) can be modulated. The modulator can
include an amplitude modulator, phase modulator, or polarization
modulator. The modulation may alter the intensity of the energy
beam. The modulation may alter the current supplied to the energy
source (e.g., direct modulation). The modulation may affect the
energy beam (e.g., external modulation such as external light
modulator). The modulation may include direct modulation (e.g., by
a modulator). The modulation may include an external modulator. The
modulator can include an aucusto-optic modulator or an
electro-optic modulator. The modulator can comprise an absorptive
modulator or a refractive modulator. The modulation may alter the
absorption coefficient the material that is used to modulate the
energy beam. The modulator may alter the refractive index of the
material that is used to modulate the energy beam.
[0184] In some embodiments, the energy beam(s), energy source(s),
and/or the platform of the energy beam array is moved. The energy
beam(s), energy source(s), and/or the platform of the energy beam
array can be moved via a galvanometer scanner (e.g., moving the
energy beam(s)), a polygon, a mechanical stage (e.g., X-Y stage), a
piezoelectric device, gimble, or any combination of thereof. The
galvanometer may comprise a mirror. The galvanometer scanner may
comprise a two-axis galvanometer scanner. The scanner may comprise
a modulator (e.g., as described herein). The scanner may comprise a
polygonal mirror. The scanner can be the same scanner for two or
more energy sources and/or beams. At least two (e.g., each) energy
source and/or beam may have a separate scanner. The energy sources
can be translated independently of each other. In some cases, at
least two energy sources and/or beams can be translated at
different rates, and/or along different paths. For example, the
movement of a first energy source may be faster as compared to the
movement of a second energy source. The systems and/or apparatuses
disclosed herein may comprise one or more shutters (e.g., safety
shutters), on/off switches, or apertures.
[0185] In some embodiments, the energy beam (e.g., laser) has a FLS
(e.g., a diameter) of its footprint on the exposed surface of the
material bed of at least about 1 micrometer (.mu.m), 5 .mu.m, 10
.mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m, 60 .mu.m, 70 .mu.m,
80 .mu.m, 90 .mu.m, 100 .mu.m, 200 .mu.m, 300 .mu.m, 400 .mu.m, or
500 .mu.m. The energy beam may have a FLS on the layer of it
footprint on the exposed surface of the material bed of at most
about 1 .mu.m, 5 .mu.m, 10 .mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50
.mu.m, 60 .mu.m, 70 .mu.m, 80 .mu.m, 90 .mu.m, 100 .mu.m, 200
.mu.m, 300 .mu.m, 400 .mu.m, or 500 .mu.m. The energy beam may have
a FLS on the exposed surface of the material bed (e.g., FIG. 3,
302) between any of the afore-mentioned energy beam FLS values
(e.g., from about 5 .mu.m to about 500 .mu.m, from about 5 .mu.m to
about 50 .mu.m, or from about 50 .mu.m to about 500 .mu.m). The
beam may be a focused beam. The beam may be a dispersed beam. The
beam may be an aligned beam. The apparatus and/or systems described
herein may further comprise a focusing coil, a deflection coil, or
an energy beam power supply. The defocused energy beam may have a
FLS of at least about 1 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50
mm, or 100 mm. The defocused energy beam may have a FLS of at most
about 1 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, or 100 mm. The
energy beam may have a defocused cross-sectional FLS on the layer
of pre-transformed material between any of the afore-mentioned
energy beam FLS values (e.g., from about 5 mm to about 100 mm, from
about 5 mm to about 50 mm, or from about 50 mm to about 100
mm).
[0186] In some embodiments, the 3D printer comprises a power
supply. The power supply to any of the components described herein
can be supplied by a grid, generator, local, or any combination
thereof. The power supply can be from renewable or non-renewable
sources. The renewable sources may comprise solar, wind,
hydroelectric, or biofuel. The powder supply can comprise
rechargeable batteries.
[0187] In some embodiments, the exposure time of the energy beam is
at least 1 microsecond (.mu.s), 5 .mu.s, 10 .mu.s, 20 .mu.s, 30
.mu.s, 40 .mu.s, 50 .mu.s, 60 .mu.s, 70 .mu.s, 80 .mu.s, 90 .mu.s,
100 .mu.s, 200 .mu.s, 300 .mu.s, 400 .mu.s, 500 .mu.s, 800 .mu.s,
or 1000 .mu.s. The exposure time of the energy beam may be most
about 1 .mu.s, 5 .mu.s, 10 .mu.s, 20 .mu.s, 30 .mu.s, 40 .mu.s, 50
.mu.s, 60 .mu.s, 70 .mu.s, 80 .mu.s, 90 .mu.s, 100 .mu.s, 200
.mu.s, 300 .mu.s, 400 .mu.s, 500 .mu.s, 800 .mu.s, or 1000 .mu.s.
The exposure time of the energy beam may be any value between the
afore-mentioned exposure time values (e.g., from about 1 .mu.s to
about 1000 .mu.s, from about 1 .mu.s to about 200 .mu.s, from about
1 .mu.s to about 500 .mu.s, from about 200 .mu.s to about 500
.mu.s, or from about 500 .mu.s to about 1000 .mu.s).
[0188] In some embodiments, the 3D printer comprises at least one
controller. The controller may control one or more characteristics
of the energy beam (e.g., variable characteristics). The control of
the energy beam may allow a low degree of material evaporation
during the 3D printing process. For example, controlling on or more
energy beam characteristics may (e.g., substantially) reduce the
amount of spatter generated during the 3D printing process. The low
degree of material evaporation may be measured in grams of
evaporated material and compared to a Kilogram of hardened material
formed as part of the 3D object. The low degree of material
evaporation may be evaporation of at most about 0.25 grams (gr.),
0.5 gr, 1 gr, 2 gr, 5 gr, 10 gr, 15 gr, 20 gr, 30 gr, or 50 gr per
every Kilogram of hardened material formed as part of the 3D
object. The low degree of material evaporation per every Kilogram
of hardened material formed as part of the 3D object may be any
value between the afore-mentioned values (e.g., from about 0.25 gr
to about 50 gr, from about 0.25 gr to about 30 gr, from about 0.25
gr to about 10 gr, from about 0.25 gr to about 5 gr, or from about
0.25 gr to about 2 gr).
[0189] The methods, systems and/or the apparatus described herein
can further comprise at least one energy source. In some cases, the
system can comprise two, three, four, five, or more energy sources.
An energy source can be a source configured to deliver energy to an
area (e.g., a confined area). An energy source can deliver energy
to the confined area through radiative heat transfer.
[0190] In some embodiments, the energy source supplies any of the
energies described herein (e.g., energy beams). The energy source
may deliver energy to a point or to an area. The energy source may
include an electron gun source. The energy source may include a
laser source. The energy source may comprise an array of lasers. In
an example, a laser can provide light energy at a peak wavelength
of at least about 100 nanometer (nm), 500 nm, 1000 nm, 1010 nm,
1020 nm, 1030 nm, 1040 nm, 1050 nm, 1060 nm, 1070 nm, 1080 nm, 1090
nm, 1100 nm, 1200 nm, 1500 nm, 1600 nm, 1700 nm, 1800 nm, 1900 nm,
or 2000 nm. In an example a laser can provide light energy at a
peak wavelength of at most about 100 nanometer (nm), 500 nm, 1000
nm, 1010 nm, 1020 nm, 1030 nm, 1040 nm, 1050 nm, 1060 nm, 1070 nm,
1080 nm, 1090 nm, 1100 nm, 1200 nm, 1500 nm, 1600 nm, 1700 nm, 1800
nm, 1900 nm, or 2000 nm. In an example a laser can provide light
energy at a peak wavelength between the afore-mentioned peak
wavelengths (e.g., from 100 nm to 2000 nm, from 100 nm to 1100 nm,
or from 1000 nm to 2000 nm). The energy beam can be incident on the
top surface of the material bed. The energy beam can be incident
on, or be directed to, a specified area of the material bed over a
specified time period. The energy beam can be substantially
perpendicular to the top (e.g., exposed) surface of the material
bed. The material bed can absorb the energy from the energy beam
(e.g., incident energy beam) and, as a result, a localized region
of the material in the material bed can increase in temperature.
The increase in temperature may transform the material within the
material bed. The increase in temperature may heat and transform
the material within the material bed. In some embodiments, the
increase in temperature may heat and not transform the material
within the material bed. The increase in temperature may heat the
material within the material bed.
[0191] In some embodiments, the energy beam and/or source is
moveable. The energy beam and/or source can be moveable such that
it can translate relative to the material bed. The energy beam
and/or source can be moved by a scanner. The movement of the energy
beam and/or source can comprise utilization of a scanner. In some
embodiments, the energy source is stationary.
[0192] At one point in time, and/or (e.g., substantially) during
the entire build of the 3D object: At least two of the energy beams
and/or sources can be translated independently of each other or in
concert with each other. At least two of the multiplicity of energy
beams can be translated independently of each other or in concert
with each other. In some cases, at least two of the energy beams
can be translated at different rates such that the movement of the
one is faster compared to the movement of at least one other energy
beam. In some cases, at least two of the energy sources can be
translated at different rates such that the movement of the one
energy source is faster compared to the movement of at least
another energy source. In some cases, at least two of the energy
sources (e.g., all of the energy sources) can be translated at
different paths. In some cases, at least two of the energy sources
can be translated at substantially identical paths. In some cases,
at least two of the energy sources can follow one another in time
and/or space. In some cases, at least two of the energy sources
translate substantially parallel to each other in time and/or
space. The power per unit area of at least two of the energy beam
may be (e.g., substantially) identical. The power per unit area of
at least one of the energy beams may be varied (e.g., during the
formation of the 3D object). The power per unit area of at least
one of the energy beams may be different. The power per unit area
of at least one of the energy beams may be different. The power per
unit area of one energy beam may be greater than the power per unit
area of a second energy beam. The energy beams may have the same or
different wavelengths. A first energy beam may have a wavelength
that is smaller or larger than the wavelength of a second energy
beam. The energy beams can derive from the same energy source. At
least one of the energy beams can derive from different energy
sources. The energy beams can derive from different energy sources.
At least two of the energy beams may have the same power (e.g., at
one point in time, and/or (e.g., substantially) during the entire
build of the 3D object). At least one of the beams may have a
different power (e.g., at one point in time, and/or substantially
during the entire build of the 3D object). The beams may have
different powers (e.g., at one point in time, and/or (e.g.,
substantially) during the entire build of the 3D object). At least
two of the energy beams may travel at (e.g., substantially) the
same velocity. At least one of the energy beams may travel at
different velocities. The velocity of travel (e.g. speed) of at
least two energy beams may be (e.g., substantially) constant. The
velocity of travel of at least two energy beams may be varied
(e.g., during the formation of the 3D object or a portion thereof).
The travel may refer to a travel relative to (e.g., on) the exposed
surface of the material bed (e.g., powder material). The travel may
refer to a travel close to the exposed surface of the material bed.
The travel may be within the material bed. The at least one energy
beam and/or source may travel relative to the material bed.
[0193] In some embodiments, the energy (e.g., energy beam) travels
in a path. The path may comprise a hatch. The path of the energy
beam may comprise repeating a path. For example, the first energy
may repeat its own path. The second energy may repeat its own path,
or the path of the first energy. The repetition may comprise a
repetition of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 times or more. The
energy may follow a path comprising parallel lines. For example,
FIG. 6, 615 or 614 show paths that comprise parallel lines. The
lines may be hatch lines. The distance between each of the parallel
lines or hatch lines, may be at least about 1 .mu.m, 5 .mu.m, 10
.mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m, 60 .mu.m, 70 .mu.m,
80 .mu.m, 90 .mu.m, or more. The distance between each of the
parallel lines or hatch lines, may be at most about 1 .mu.m, 5
.mu.m, 10 .mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m, 60 .mu.m,
70 .mu.m, 80 .mu.m, 90 .mu.m, or less. The distance between each of
the parallel lines or hatch lines may be any value between any of
the afore-mentioned distance values (e.g., from about 1 .mu.m to
about 90 .mu.m, from about 1 .mu.m to about 50 .mu.m, or from about
40 .mu.m to about 90 .mu.m). The distance between the parallel or
parallel lines or hatch lines may be substantially the same in
every layer (e.g., plane) of transformed material. The distance
between the parallel lines or hatch lines in one layer (e.g.,
plane) of transformed material may be different than the distance
between the parallel lines or hatch lines respectively in another
layer (e.g., plane) of transformed material within the 3D object.
The distance between the parallel lines or hatch lines portions
within a layer (e.g., plane) of transformed material may be
substantially constant. The distance between the parallel lines or
hatch lines within a layer (e.g., plane) of transformed material
may be varied. The distance between a first pair of parallel lines
or hatch lines within a layer (e.g., plane) of transformed material
may be different than the distance between a second pair of
parallel lines or hatch lines within a layer (e.g., plane) of
transformed material respectively. The first energy beam may follow
a path comprising two hatch lines or paths that cross in at least
one point. The hatch lines or paths may be straight or curved. The
hatch lines or paths may be winding. FIG. 6, 610 or 611 show
examples of winding paths. The first energy beam may follow a hatch
line or path comprising a U shaped turn (e.g., FIG. 6, 610). The
first energy beam may follow a hatch line or path devoid of U
shaped turns (e.g., FIG. 612).
[0194] In some embodiments, the formation of the 3D object includes
transforming (e.g., fusing, binding or connecting) the
pre-transformed material (e.g., powder material) using an energy
beam. The energy beam may be projected on to a particular area of
the material bed, thus causing the pre-transformed material to
transform. The energy beam may cause at least a portion of the
pre-transformed material to transform from its present state of
matter to a different state of matter. For example, the
pre-transformed material may transform at least in part (e.g.,
completely) from a solid to a liquid state. The energy beam may
cause at least a portion of the pre-transformed material to
chemically transform. For example, the energy beam may cause
chemical bonds to form or break. The chemical transformation may be
an isomeric transformation. The transformation may comprise a
magnetic transformation or an electronic transformation. The
transformation may comprise coagulation of the material, cohesion
of the material, or accumulation of the material.
[0195] The methods described herein may further comprise repeating
the operations of material deposition and material transformation
operations to produce a 3D object (or a portion thereof) by at
least one 3D printing (e.g., additive manufacturing) method. For
example, the methods described herein may further comprise
repeating the operations of depositing a layer of pre-transformed
material and transforming at least a portion of the pre-transformed
material to connect to the previously formed 3D object portion
(e.g., repeating the 3D printing cycle), thus forming at least a
portion of a 3D object. The transforming operation may comprise
utilizing an energy beam to transform the material. In some
instances, the energy beam is utilized to transform at least a
portion of the material bed (e.g., utilizing any of the methods
described herein).
[0196] In some embodiments, the transforming energy is provided by
an energy source. The transforming energy may comprise an energy
beam. The energy source can produce an energy beam. The energy beam
may include a radiation comprising electromagnetic, electron,
positron, proton, plasma, or ionic radiation. The electromagnetic
beam may comprise microwave, infrared, ultraviolet, or visible
radiation. The ion beam may include a charged particle beam. The
ion beam may include a cation, or an anion. The electromagnetic
beam may comprise a laser beam. The laser may comprise a fiber, or
a solid-state laser beam. The energy source may include a laser.
The energy source may include an electron gun. The energy depletion
may comprise heat depletion. The energy depletion may comprise
cooling. The energy may comprise an energy flux (e.g., energy beam.
E.g., radiated energy). The energy may comprise an energy beam. The
energy may be the transforming energy. The energy may be a warming
energy that is not able to transform the deposited pre-transformed
material (e.g., in the material bed). The warming energy may be
able to raise the temperature of the deposited pre-transformed
material. The energy beam may comprise energy provided at a (e.g.,
substantially) constant or varied energy beam characteristics. The
energy beam may comprise energy provided at (e.g., substantially)
constant or varied energy beam characteristics, depending on the
position of the generated hardened material within the 3D object.
The varied energy beam characteristics may comprise energy flux,
rate, intensity, wavelength, amplitude, power, cross-section, or
time exerted for the energy process (e.g., transforming or
heating). The energy beam footprint may be the average (or mean)
FLS of the foot print of the energy beam on the exposed surface of
the material bed. The FLS may be a diameter, a spherical equivalent
diameter, a length, a height, a width, or diameter of a bounding
circle. The FLS may be the larger of a length, a height, and a
width of a 3D form.
[0197] In some embodiments, the energy beam follows a path. The
path of the energy beam may be a vector. The path of the energy
beam may comprise a raster, a vector, or any combination thereof.
The path of the energy beam may comprise an oscillating pattern.
The path of the energy beam may comprise a zigzag, wave (e.g.,
curved, triangular, or square), or curve pattern. The curved wave
may comprise a sine or cosine wave. The path of the energy beam may
comprise a sub-pattern. The path of the energy beam may comprise an
oscillating (e.g., zigzag), wave (e.g., curved, triangular, or
square), and/or curved sub-pattern. The curved wave may comprise a
sine or cosine wave. FIG. 5 shows an example of a path 501 of an
energy beam comprising a zigzag sub-pattern (e.g., 502 shown as an
expansion (e.g., blow-up) of a portion of the path 501). The
sub-path of the energy beam may comprise a wave (e.g., sine or
cosine wave) pattern. The sub-path may be a small path that forms
the large path. The sub-path may be a component (e.g., a portion)
of the large path. The path that the energy beam follows may be a
predetermined path. A model may predetermine the path by utilizing
a controller or an individual (e.g., human). The controller may
comprise a processor. The processor may comprise a computer,
computer program, drawing or drawing data, statue or statue data,
or any combination thereof.
[0198] In some embodiments, the path comprises successive lines.
The successive lines may touch each other. The successive lines may
overlap each other in at least one point. The successive lines may
substantially overlap each other. The successive lines may be
spaced by a first distance (e.g., hatch spacing). FIG. 6 shows an
example of a path 614 that includes five hatches wherein each two
immediately adjacent hatches are separated by a spacing distance.
The hatch spacing may be any hatch spacing disclosed in Patent
Application serial number PCT/US16/34857 filed on May 27, 2016,
titled "THREE-DIMENSIONAL PRINTING AND THREE-DIMENSIONAL OBJECTS
FORMED USING THE SAME" that is entirely incorporated herein by
reference.
[0199] In some embodiments, the term "auxiliary support," as used
herein, generally refers to at least one feature that is a part of
a printed 3D object, but not part of the desired, intended,
designed, ordered, and/or final 3D object. Auxiliary support may
provide structural support during and/or subsequent to the
formation of the 3D object. The auxiliary support may be anchored
to the enclosure. For example, an auxiliary support may be anchored
to the platform (e.g., building platform), to the side walls of the
material bed, to a wall of the enclosure, to an object (e.g.,
stationary or semi-stationary) within the enclosure, or any
combination thereof. The auxiliary support may be the platform
(e.g., the base, the substrate, or the bottom of the enclosure).
The auxiliary support may enable the removal or energy from the 3D
object (e.g., or a portion thereof) that is being formed. The
removal of energy (e.g., heat) may be during and/or after the
formation of the 3D object. Examples of auxiliary support comprise
a fin (e.g., heat fin), anchor, handle, pillar, column, frame,
footing, wall, platform, or another stabilization feature. In some
instances, the auxiliary support may be mounted, clamped, or
situated on the platform. The auxiliary support can be anchored to
the building platform, to the sides (e.g., walls) of the building
platform, to the enclosure, to an object (stationary or
semi-stationary) within the enclosure, or any combination
thereof.
[0200] In some examples, the generated 3D object can be printed
without auxiliary support. In some examples, overhanging feature of
the generated 3D object can be printed without (e.g., without any)
auxiliary support. The generated object can be devoid of auxiliary
supports. The generated object may be suspended (e.g., float
anchorlessly) in the material bed (e.g., powder bed). The term
"anchorlessly," as used herein, generally refers to without or in
the absence of an anchor. In some examples, an object is suspended
in a powder bed anchorlessly without attachment to a support. For
example, the object floats in the powder bed. The generated 3D
object may be suspended in the layer of pre-transformed material
(e.g., powder material). The pre-transformed material (e.g., powder
material) can offer support to the printed 3D object (or the object
during its generation). Sometimes, the generated 3D object may
comprise one or more auxiliary supports. The auxiliary support may
be suspended in the pre-transformed material (e.g., powder
material). The auxiliary support may provide weights or
stabilizers. The auxiliary support can be suspended in the material
bed within the layer of pre-transformed material in which the 3D
object (or a portion thereof) has been formed. The auxiliary
support (e.g., one or more auxiliary supports) can be suspended in
the pre-transformed material within a layer of pre-transformed
material other than the one in which the 3D object (or a portion
thereof) has been formed (e.g., a previously deposited layer of
(e.g., powder) material). The auxiliary support may touch the
platform. The auxiliary support may be suspended in the material
bed (e.g., powder material) and not touch the platform. The
auxiliary support may be anchored to the platform. The distance
between any two auxiliary supports can be at least about 1
millimeter, 1.3 millimeters (mm), 1.5 mm, 1.8 mm, 1.9 mm, 2.0 mm,
2.2 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 3 mm, 4 mm, 5 mm, 10 mm, 11
mm, 15 mm, 20 mm, 30 mm, 40 mm, 41 mm, or 45 mm. The distance
between any two auxiliary supports can be at most 1 millimeter, 1.3
mm, 1.5 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.2 mm, 2.4 mm, 2.5 mm, 2.6 mm,
2.7 mm, 3 mm, 4 mm, 5 mm, 10 mm, 11 mm, 15 mm, 20 mm, 30 mm, 40 mm,
41 mm, or 45 mm. The distance between any two auxiliary supports
can be any value in between the afore-mentioned distances (e.g.,
from about 1 mm to about 45 mm, from about 1 mm to about 11 mm,
from about 2.2 mm to about 15 mm, or from about 10 mm to about 45
mm). At times, a sphere intersecting an exposed surface of the 3D
object may be devoid of auxiliary support. The sphere may have a
radius XY that is equal to the distance between any two auxiliary
supports mentioned herein.
[0201] In some examples, the diminished number of auxiliary
supports or lack of auxiliary support, may facilitate a 3D printing
process that requires a smaller amount of material, produces a
smaller amount of material waste, and/or requires smaller energy as
compared to commercially available 3D printing processes. The
reduced number of auxiliary supports can be smaller by at least
about 1.1, 1.3, 1.5, 2, 3, 4, 5, 6, 7, 8, 9, or 10 as compared to
conventional 3D printing. The smaller amount may be smaller by any
value between the aforesaid values (e.g., from about 1.1 to about
10, or from about 1.5 to about 5) as compared to conventional 3D
printing.
[0202] In some examples, the generated 3D object has a surface
roughness profile. The generated 3D object can have various surface
roughness profiles, which may be suitable for various applications.
The surface roughness may be the deviations in the direction of the
normal vector of a real surface from its ideal form. The generated
3D object can have a Ra value of as disclosed herein.
[0203] The generated 3D object (e.g., the hardened cover) may be
substantially smooth. The generated 3D object may have a deviation
from an ideal planar surface (e.g., atomically flat or molecularly
flat) of at most about 1.5 nanometers (nm), 2 nm, 3 nm, 4 nm, 5 nm,
10 nm, 15 nm, 20 nm, 25 nm, 30 nm, 35 nm, 100 nm, 300 nm, 500 nm, 1
micrometer (.mu.m), 1.5 .mu.m, 2 .mu.m, 3 .mu.m, 4 .mu.m, 5 .mu.m,
10 .mu.m, 15 .mu.m, 20 .mu.m, 25 .mu.m, 30 .mu.m, 35 .mu.m, 100
.mu.m, 300 .mu.m, 500 .mu.m, or less. The generated 3D object may
have a deviation from an ideal planar surface of at least about 1.5
nanometers (nm), 2 nm, 3 nm, 4 nm, 5 nm, 10 nm, 15 nm, 20 nm, 25
nm, 30 nm, 35 nm, 100 nm, 300 nm, 500 nm, 1 micrometer (.mu.m), 1.5
.mu.m, 2 .mu.m, 3 .mu.m, 4 .mu.m, 5 .mu.m, 10 .mu.m, 15 .mu.m, 20
.mu.m, 25 .mu.m, 30 .mu.m, 35 .mu.m, 100 .mu.m, 300 .mu.m, 500
.mu.m, or more. The generated 3D object may have a deviation from
an ideal planar surface between any of the afore-mentioned
deviation values. The generated 3D object may comprise a pore. The
generated 3D object may comprise pores. The pores may be of an
average FLS (diameter or diameter equivalent in case the pores are
not spherical) of at most about 1.5 nanometers (nm), 2 nm, 3 nm, 4
nm, 5 nm, 10 nm, 15 nm, 20 nm, 25 nm, 30 nm 35 nm, 100 nm, 300 nm,
500 nm, 1 micrometer (.mu.m), 1.5 .mu.m, 2 .mu.m, 3 .mu.m, 4 .mu.m,
5 .mu.m, 10 .mu.m, 15 .mu.m, 20 .mu.m, 25 .mu.m, 30 .mu.m, 35
.mu.m, 100 .mu.m, 300 .mu.m, or 500 .mu.m. The pores may be of an
average FLS of at least about 1.5 nanometers (nm), 2 nm, 3 nm, 4
nm, 5 nm, 10 nm, 15 nm, 20 nm, 25 nm, 30 nm, 35 nm, 100 nm, 300 nm,
500 nm, 1 micrometer (.mu.m), 1.5 .mu.m, 2 .mu.m, 3 .mu.m, 4 .mu.m,
5 .mu.m, 10 .mu.m, 15 .mu.m, 20 .mu.m, 25 .mu.m, 30 .mu.m, 35
.mu.m, 100 .mu.m, 300 .mu.m, or 500 .mu.m. The pores may be of an
average FLS between any of the afore-mentioned FLS values (e.g.,
from about 1 nm to about 500 .mu.m, or from about 20 .mu.m, to
about 300 .mu.m). The 3D object (or at least a layer thereof) may
have a porosity of at most about 0.05 percent (%), 0.1% 0.2%, 0.3%,
0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%,
9%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80%. The 3D object (or at
least a layer thereof) may have a porosity of at least about 0.05%,
0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%,
4%, 5%, 6%, 7%, 8%, 9%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80%.
The 3D object (or at least a layer thereof) may have porosity
between any of the afore-mentioned porosity percentages (e.g., from
about 0.05% to about 80%, from about 0.05% to about 40%, from about
10% to about 40%, or from about 40% to about 90%). In some
instances, a pore may traverse the generated 3D object. For
example, the pore may start at a face of the 3D object and end at
the opposing face of the 3D object. The pore may comprise a
passageway extending from one face of the 3D object and ending on
the opposing face of that 3D object. In some instances, the pore
may not traverse the generated 3D object. The pore may form a
cavity in the generated 3D object. The pore may form a cavity on a
face of the generated 3D object. For example, pore may start on a
face of the plane and not extend to the opposing face of that 3D
object.
[0204] In some examples, the formed plane comprises a protrusion.
The protrusion can be a grain, a bulge, a bump, a ridge, or an
elevation. The generated 3D object may comprise protrusions. The
protrusions may be of an average FLS of at most about 1.5
nanometers (nm), 2 nm, 3 nm, 4 nm, 5 nm, 10 nm, 15 nm, 20 nm, 25
nm, 30 nm, 35 nm, 100 nm, 300 nm, 500 nm, 1 micrometer (.mu.m), 1.5
.mu.m, 2 .mu.m, 3 .mu.m, 4 .mu.m, 5 .mu.m, 10 .mu.m, 15 .mu.m, 20
.mu.m, 25 .mu.m, 30 .mu.m, 35 .mu.m, 100 .mu.m, 300 .mu.m, 500
.mu.m, or less. The protrusions may be of an average FLS of at
least about 1.5 nanometers (nm), 2 nm, 3 nm, 4 nm, 5 nm, 10 nm, 15
nm, 20 nm, 25 nm, 30 nm, 35 nm, 100 nm, 300 nm, 500 nm, 1
micrometer (.mu.m), 1.5 .mu.m, 2 .mu.m, 3 .mu.m, 4 .mu.m, 5 .mu.m,
10 .mu.m, 15 .mu.m, 20 .mu.m, 25 .mu.m, 30 .mu.m, 35 .mu.m, 100
.mu.m, 300 .mu.m, 500 .mu.m, or more. The protrusions may be of an
average FLS between any of the afore-mentioned FLS values. The
protrusions may constitute at most about 0.05%, 0.1%, 0.2%, 0.3%,
0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 10%, 20%,
30%, 40%, or 50% of the area of the generated 3D object. The
protrusions may constitute at least about 0.05%, 0.1%, 0.2%, 0.3%,
0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 10%, 20%,
30%, 40%, or 50% of the area of the 3D object. The protrusions may
constitute a percentage of an area of the 3D object that is between
the afore-mentioned percentages of 3D object area. The protrusion
may reside on any surface of the 3D object. For example, the
protrusions may reside on an external surface of a 3D object. The
protrusions may reside on an internal surface (e.g., a cavity) of a
3D object. At times, the average size of the protrusions and/or of
the holes may determine the resolution of the printed (e.g.,
generated) 3D object. The resolution of the printed 3D object may
be at least about 1 micrometer, 1.3 micrometers (.mu.m), 1.5 .mu.m,
1.8 .mu.m, 1.9 .mu.m, 2.0 .mu.m, 2.2 .mu.m, 2.4 .mu.m, 2.5 .mu.m,
2.6 .mu.m, 2.7 .mu.m, 3 .mu.m, 4 .mu.m, 5 .mu.m, 10 .mu.m, 20
.mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m, 60 .mu.m, 70 .mu.m, 80 .mu.m,
90 .mu.m, 100 .mu.m, 200 .mu.m, or more. The resolution of the
printed 3D object may be at most about 1 micrometer, 1.3
micrometers (.mu.m), 1.5 .mu.m, 1.8 .mu.m, 1.9 .mu.m, 2.0 .mu.m,
2.2 .mu.m, 2.4 .mu.m, 2.5 .mu.m, 2.6 .mu.m, 2.7 .mu.m, 3 .mu.m, 4
.mu.m, 5 .mu.m, 10 .mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m,
60 .mu.m, 70 .mu.m, 80 .mu.m, 90 .mu.m, 100 .mu.m, 200 .mu.m, or
less. The resolution of the printed 3D object may be any value
between the above-mentioned resolution values. At times, the 3D
object may have a material density of at least about 99.9%, 99.8%,
99.7%, 99.6%, 99.5%, 99.4%, 99.3%, 99.2% 99.1%, 99%, 98%, 96%, 95%,
94%, 93%, 92%, 91%, 90%, 8%, or 70%. At times, the 3D object may
have a material density of at most about 99.5%, 99%, 98%, 96%, 95%,
94%, 93%, 92%, 91%, 90%, 8%, or 70%. At times, the 3D object may
have a material density between the afore-mentioned material
densities. The resolution of the 3D object may be at least about
100 dots per inch (dpi), 300 dpi, 600 dpi, 1200 dpi, 2400 dpi, 3600
dpi, or 4800 dpi. The resolution of the 3D object may be at most
about 100 dpi, 300 dpi, 600 dpi, 1200 dpi, 2400 dpi, 3600 dpi, or
4800dip. The resolution of the 3D object may be any value between
the afore-mentioned values (e.g., from 100 dpi to 4800 dpi, from
300 dpi to 2400 dpi, or from 600 dpi to 4800 dpi). The height
uniformity (e.g., deviation from average surface height) of a
planar surface of the 3D object may be at least about 100 .mu.m, 90
.mu.m, 80 .mu.m, 70 .mu.m, 60 .mu.m, 50 .mu.m, 40 .mu.m, 30 .mu.m,
20 .mu.m, 10 .mu.m, or 5 .mu.m. The height uniformity of the planar
surface may be at most about 100 .mu.m, 90 .mu.m, 80, 70 .mu.m, 60
.mu.m, 50 .mu.m, 40 .mu.m, 30 .mu.m, 20 .mu.m, 10 .mu.m, or 5
.mu.m. The height uniformity of the planar surface of the 3D object
may be any value between the afore-mentioned height deviation
values (e.g., from about 100 .mu.m to about 5 .mu.m, from about 50
.mu.m to about 5 .mu.m, from about 30 .mu.m to about 5 .mu.m, or
from about 20 .mu.m to about 5 .mu.m). The height uniformity may
comprise high precision uniformity.
[0205] In some examples, the energy is transferred from the
material bed to the cooling member. Energy (e.g., heat) can be
transferred from the material bed to the cooling member (e.g., heat
sink) through any one or combination of heat transfer mechanisms.
FIG. 1, 113 shows an example of a cooling member. The heat transfer
mechanism may comprise conduction, radiation, or convection. The
convection may comprise natural or forced convection. The cooling
member can be solid, liquid, gas, or semi-solid. In some examples,
the cooling member (e.g., heat sink) is solid. The cooling member
may be located above, below, or to the side of the powder layer.
The cooling member may comprise an energy conductive material. The
cooling member may comprise an active energy transfer or a passive
energy transfer. The cooling member may comprise a cooling liquid
(e.g., aqueous or oil), cooling gas, or cooling solid. The cooling
member may be further connected to a cooler and/or a thermostat.
The gas, semi-solid, or liquid comprised in the cooling member may
be stationary or circulating. The cooling member may comprise a
material that conducts heat efficiently. The heat (thermal)
conductivity of the cooling member may be at least about 20 Watts
per meter times Kelvin (W/mK), 50 W/mK, 100 W/mK, 150 W/mK, 200
W/mK, 205 W/mK, 300 W/mK, 350 W/mK, 400 W/mK, 450 W/mK, 500 W/mK,
550 W/mK, 600 W/mK, 700 W/mK, 800 W/mK, 900 W/mK, or 1000 W/mK. The
heat conductivity of the heat sink may be at most about 20 W/mK, 50
W/mK, 100 W/mK, 150 W/mK, 200 W/mK, 205 W/mK, 300 W/mK, 350 W/mK,
400 W/mK, 450 W/mK, 500 W/mK, 550 W/mK, 600 W/mK, 700 W/mK, 800
W/mK, 900 W/mK, or 1000 W/mK. The heat conductivity of the heat
sink may any value between the afore-mentioned heat conductivity
values. The heat (thermal) conductivity of the cooling member may
be measured at ambient temperature (e.g., room temperature) and/or
pressure. For example, the heat conductivity may be measured at
about 20.degree. C. and a pressure of 1 atmosphere. The heat sink
can be separated from the powder bed or powder layer by a gap. The
gap can be filled with a gas. The cooling member may be any cooling
member (e.g., that is used in 3D printing) such as, for example,
the ones described in Patent Application serial number
PCT/US15/36802, or in Provisional Patent Application Ser. No.
62/317,070, both of which are entirely incorporated herein by
references.
[0206] In some examples, when the energy source is in operation,
the material bed reaches a certain (e.g., average) temperature. The
average temperature of the material bed can be an ambient
temperature or "room temperature." The average temperature of the
material bed can have an average temperature during the operation
of the energy (e.g., beam). The average temperature of the material
bed can be an average temperature during the formation of the
transformed material, the formation of the hardened material, or
the generation of the 3D object. The average temperature can be
below or just below the transforming temperature of the material.
Just below can refer to a temperature that is at most about
1.degree. C., 2.degree. C., 3.degree. C., 4.degree. C., 5.degree.
C., 6.degree. C., 7.degree. C., 8.degree. C., 9.degree. C.,
10.degree. C., 15.degree. C., or 20.degree. C. below the
transforming temperature. The average temperature of the material
bed (e.g., pre-transformed material) can be at most about
10.degree. C. (degrees Celsius), 20.degree. C., 25.degree. C.,
30.degree. C., 40.degree. C., 50.degree. C., 60.degree. C.,
70.degree. C., 80.degree. C., 90.degree. C., 100.degree. C.,
120.degree. C., 140.degree. C., 150.degree. C., 160.degree. C.,
180.degree. C., 200.degree. C., 250.degree. C., 300.degree. C.,
400.degree. C., 500.degree. C., 600.degree. C., 700.degree. C.,
800.degree. C., 900.degree. C., 1000.degree. C., 1200.degree. C.,
1400.degree. C., 1600.degree. C., 1800.degree. C., or 2000.degree.
C. The average temperature of the material bed (e.g.,
pre-transformed material) can be at least about 10.degree. C.,
20.degree. C., 25.degree. C., 30.degree. C., 40.degree. C.,
50.degree. C., 60.degree. C., 70.degree. C., 80.degree. C.,
90.degree. C., 100.degree. C., 120.degree. C., 140.degree. C.,
150.degree. C., 160.degree. C., 180.degree. C., 200.degree. C.,
250.degree. C., 300.degree. C., 400.degree. C., 500.degree. C.,
600.degree. C., 700.degree. C., 800.degree. C., 900.degree. C.,
1000.degree. C., 1200.degree. C., 1400.degree. C., 1600.degree. C.,
1800.degree. C., or 2000.degree. C. The average temperature of the
material bed (e.g., pre-transformed material) can be any
temperature between the afore-mentioned material average
temperatures. The average temperature of the material bed (e.g.,
pre-transformed material) may refer to the average temperature
during the 3D printing. The pre-transformed material can be the
material within the material bed that has not been transformed and
generated at least a portion of the 3D object (e.g., the
remainder). The material bed can be heated or cooled before,
during, or after forming the 3D object (e.g., hardened material).
Bulk heaters can heat the material bed. The bulk heaters can be
situated adjacent to (e.g., above, below, or to the side of) the
material bed, or within a material dispensing system. For example,
the material can be heated using radiators (e.g., quartz radiators,
or infrared emitters). The material bed temperature can be
substantially maintained at a predetermined value. The temperature
of the material bed can be monitored. The material temperature can
be controlled manually and/or by a control system.
[0207] In some examples, the pre-transformed material is heated.
The pre-transformed material within the material bed can be heated
by a first energy source such that the heating will transform the
pre-transformed material. The remainder of the material that did
not transform to generate at least a portion of the 3D object
(e.g., the remainder) can be heated by a second energy source. The
remainder can be at an average temperature that is less than the
liquefying temperature of the material (e.g., during the 3D
printing). The maximum temperature of the transformed portion of
the material bed and the average temperature of the remainder of
the material bed can be different. The solidus temperature of the
material can be a temperature wherein the material is in a solid
state at a given pressure (e.g., ambient pressure). Ambient may
refer to the surrounding. After the portion of the material bed is
heated to the temperature that is at least a liquefying temperature
of the material by the first energy source, that portion of the
material may be cooled to allow the transformed (e.g., liquefied)
material portion to harden (e.g., solidify). In some cases, the
liquefying temperature can be at least about 100.degree. C.,
200.degree. C., 300.degree. C., 400.degree. C., or 500.degree. C.,
and the solidus temperature can be at most about 500.degree. C.,
400.degree. C., 300.degree. C., 200.degree. C., or 100.degree. C.
For example, the liquefying temperature is at least about
300.degree. C. and the solidus temperature is less than about
300.degree. C. In another example, the liquefying temperature is at
least about 400.degree. C. and the solidus temperature is less than
about 400.degree. C. The liquefying temperature may be different
from the solidus temperature. In some instances, the temperature of
the pre-transformed material is maintained above the solidus
temperature of the material and below its liquefying temperature.
In some examples, the material from which the pre-transformed
material is composed has a super cooling temperature (or super
cooling temperature regime). In some examples, as the first energy
source heats up the pre-transformed material to cause at least a
portion of it to melt, the molten material will remain molten as
the material bed is held at or above the material super cooling
temperature of the material, but below its melting point. When two
or more materials make up the material layer at a specific ratio,
the materials may form a eutectic material on transformation of the
material. The liquefying temperature of the formed eutectic
material may be the temperature at the eutectic point, close to the
eutectic point, or far from the eutectic point. Close to the
eutectic point may designate a temperature that is different from
the eutectic temperature (i.e., temperature at the eutectic point)
by at most about 0.1.degree. C., 0.5.degree. C., 1.degree. C.,
2.degree. C., 4.degree. C., 5.degree. C., 6.degree. C., 8.degree.
C., 10.degree. C., or 15.degree. C. A temperature that is farther
from the eutectic point than the temperature close to the eutectic
point is designated herein as a temperature far from the eutectic
Point. The process of liquefying and solidifying a portion of the
material can be repeated until the entire object has been formed.
At the completion of the generated 3D object, it can be removed
from the remainder of material in the container. The remaining
material can be separated from the portion at the generated 3D
object. The generated 3D object can be hardened and removed from
the container (e.g., from the substrate or from the base).
[0208] The methods described herein may further comprise
stabilizing the temperature within the enclosure. For example,
stabilizing the temperature of the atmosphere or the
pre-transformed material (e.g., within the material bed).
Stabilization of the temperature may be to a predetermined
temperature value. The methods described herein may further
comprise altering the temperature within at least one portion of
the container. Alteration of the temperature may be to a
predetermined temperature. Alteration of the temperature may
comprise heating and/or cooling the material bed. Elevating the
temperature (e.g., of the material bed) may be to a temperature
below the temperature at which the pre-transformed material fuses
(e.g., melts or sinters), connects, or bonds.
[0209] In some examples, the 3D printer comprises an optical
system. The apparatus and/or systems described herein may comprise
an optical system. The optical components may be controlled
manually and/or via a control system (e.g., a controller). The
optical system may be configured to direct at least one energy beam
(e.g., 307) from the at least one energy source (e.g., 306) to a
position on the material bed within the enclosure (e.g., a
predetermined position). A scanner can be included in the optical
system. The printing system may comprise a processor (e.g., a
central processing unit). The processor can be programmed to
control a trajectory of the at least one energy beam and/or energy
source with the aid of the optical system. The systems and/or the
apparatus described herein can further comprise a control system in
communication with the at least one energy source and/or energy
beam. The control system can regulate a supply of energy from the
at least one energy source to the material in the container. The
control system may control the various components of the optical
system. The various components of the optical system (e.g., FIG. 3)
may include optical components comprising a mirror (e.g., 305), a
lens (e.g., concave or convex), a fiber, a beam guide, a rotating
polygon, or a prism. The lens may be a focusing or a dispersing
lens. The lens may be a diverging or converging lens. The mirror
can be a deflection mirror. The optical components may be tiltable
and/or rotatable. The optical components may be tilted and/or
rotated. The mirror may be a deflection mirror. The optical
components may comprise an aperture. The aperture may be
mechanical. The optical system may comprise a variable focusing
device. The variable focusing device may be connected to the
control system. The variable focusing device may be controlled by
the control system and/or manually. The variable focusing device
may comprise a modulator. The modulator may comprise an
acousto-optical modulator, mechanical modulator, or an electro
optical modulator. The focusing device may comprise an aperture
(e.g., a diaphragm aperture).
[0210] In some embodiments, the container comprises one or more
sensors. The container described herein may comprise at least one
sensor. The sensor may be connected and/or controlled by the
control system (e.g., computer control system, or controller). The
control system may be able to receive signals from the at least one
sensor. The control system may act upon at least one signal
received from the at least one sensor. The control may rely on
feedback and/or feed forward mechanisms that has been
pre-programmed. The feedback and/or feed forward mechanisms may
rely on input from at least one sensor that is connected to the
control unit.
[0211] In some embodiments, the sensor detects the amount material
(e.g., pre-transformed material) in the enclosure. The controller
may monitor the amount of material in the enclosure (e.g., within
the material bed). The systems and/or the apparatus described
herein can include a pressure sensor. The pressure sensor may
measure the pressure of the chamber (e.g., pressure of the chamber
atmosphere). The pressure sensor can be coupled to a control
system. The pressure can be electronically and/or manually
controlled. The controller may regulate the pressure (e.g., with
the aid of one or more vacuum pumps) according to input from at
least one pressure sensor. The sensor may comprise light sensor,
image sensor, acoustic sensor, vibration sensor, chemical sensor,
electrical sensor, magnetic sensor, fluidity sensor, movement
sensor, speed sensor, position sensor, pressure sensor, force
sensor, density sensor, metrology sensor, sonic sensor (e.g.,
ultrasonic sensor), or proximity sensor. The metrology sensor may
comprise measurement sensor (e.g., height, length, width, depth,
angle, and/or volume). The metrology sensor may comprise a
magnetic, acceleration, orientation, or optical sensor. The optical
sensor may comprise a camera (e.g., IR camera, or CCD camera (e.g.,
single line CCD camera)). or CCD camera (e.g., single line CCD
camera). The sensor may transmit and/or receive sound (e.g., echo),
magnetic, electronic, or electromagnetic signal. The
electromagnetic signal may comprise a visible, infrared,
ultraviolet, ultrasound, radio wave, or microwave signal. The
metrology sensor may measure the tile. The metrology sensor may
measure the gap. The metrology sensor may measure at least a
portion of the layer of material (e.g., pre-transformed,
transformed, and/or hardened). The layer of material may be a
pre-transformed material (e.g., powder), transformed material, or
hardened material. The metrology sensor may measure at least a
portion of the 3D object. The sensor may comprise a temperature
sensor, weight sensor, powder level sensor, gas sensor, or humidity
sensor. The gas sensor may sense any gas enumerated herein. The
temperature sensor may comprise Bolometer, Bimetallic strip,
calorimeter, Exhaust gas temperature gauge, Flame detection, Gardon
gauge, Golay cell, Heat flux sensor, Infrared thermometer,
Microbolometer, Microwave radiometer, Net radiometer, Quartz
thermometer, Resistance temperature detector, Resistance
thermometer, Silicon band gap temperature sensor, Special sensor
microwave/imager, Temperature gauge, Thermistor, Thermocouple,
Thermometer, Pyrometer, IR camera, or CCD camera (e.g., single line
CCD camera). The temperature sensor may measure the temperature
without contacting the material bed (e.g., non-contact
measurements). The pyrometer may comprise a point pyrometer, or a
multi-point pyrometer. The Infrared (IR) thermometer may comprise
an IR camera. The pressure sensor may comprise Barograph,
Barometer, Boost gauge, Bourdon gauge, hot filament ionization
gauge, Ionization gauge, McLeod gauge, Oscillating U-tube,
Permanent Downhole Gauge, Piezometer, Pirani gauge, Pressure
sensor, Pressure gauge, tactile sensor, or Time pressure gauge. The
position sensor may comprise Auxanometer, Capacitive displacement
sensor, Capacitive sensing, Free fall sensor, Gravimeter,
Gyroscopic sensor, Impact sensor, Inclinometer, Integrated circuit
piezoelectric sensor, Laser rangefinder, Laser surface velocimeter,
LIDAR, Linear encoder, Linear variable differential transformer
(LVDT), Liquid capacitive inclinometers, Odometer, Photoelectric
sensor, Piezoelectric accelerometer, Rate sensor, Rotary encoder,
Rotary variable differential transformer, Selsyn, Shock detector,
Shock data logger, Tilt sensor, Tachometer, Ultrasonic thickness
gauge, Variable reluctance sensor, or Velocity receiver. The
optical sensor may comprise a Charge-coupled device, Colorimeter,
Contact image sensor, Electro-optical sensor, Infra-red sensor,
Kinetic inductance detector, light emitting diode as light sensor,
Light-addressable potentiometric sensor, Nichols radiometer, Fiber
optic sensors, optical position sensor, photo detector, photodiode,
photomultiplier tubes, phototransistor, photoelectric sensor,
photoionization detector, photomultiplier, photo resistor, photo
switch, phototube, scintillometer, Shack-Hartmann, single-photon
avalanche diode, superconducting nanowire single-photon detector,
transition edge sensor, visible light photon counter, or wave front
sensor. The weight of the enclosure (e.g., container), or any
components within the enclosure can be monitored by at least one
weight sensor in or adjacent to the material. For example, a weight
sensor can be situated at the bottom of the enclosure. The weight
sensor can be situated between the bottom of the enclosure and the
substrate. The weight sensor can be situated between the substrate
and the base. The weight sensor can be situated between the bottom
of the container and the base. The weight sensor can be situated
between the bottom of the container and the top of the material
bed. The weight sensor can comprise a pressure sensor. The weight
sensor may comprise a spring scale, a hydraulic scale, a pneumatic
scale, or a balance. At least a portion of the pressure sensor can
be exposed on a bottom of the container. In some cases, the at
least one weight sensor can comprise a button load cell.
Alternatively, or additionally a sensor can be configured to
monitor the weight of the material by monitoring a weight of a
structure that contains the material (e.g., a material bed). One or
more position sensors (e.g., height sensors) can measure the height
of the material bed relative to the substrate. The position sensors
can be optical sensors. The position sensors can determine a
distance between one or more energy sources and a surface of the
material bed. The surface of the material bed can be the upper
surface of the material bed. For example, FIG. 1, 119 shows an
example of an upper surface of the material bed 104.
[0212] In some embodiments, the 3D printer comprises one or more
valves. The methods, systems and/or the apparatus described herein
may comprise at least one valve. The valve may be shut or opened
according to an input from the at least one sensor, or manually.
The degree of valve opening or shutting may be regulated by the
control system, for example, according to at least one input from
at least one sensor. The systems and/or the apparatus described
herein can include one or more valves, such as throttle valves.
[0213] In some embodiments, the 3D printer comprises one or more
motors. The methods, systems and/or the apparatus described herein
may comprise a motor. The motor may be controlled by the control
system and/or manually. The apparatuses and/or systems described
herein may include a system providing the material (e.g., powder
material) to the material bed. The system for providing the
material may be controlled by the control system, or manually. The
motor may connect to a system providing the material (e.g., powder
material) to the material bed. The system and/or apparatus of the
present invention may comprise a material reservoir. The material
may travel from the reservoir to the system and/or apparatus of the
present invention may comprise a material reservoir. The material
may travel from the reservoir to the system for providing the
material to the material bed. The motor may alter (e.g., the
position of) the substrate and/or to the base. The motor may alter
(e.g., the position of) the elevator. The motor may alter an
opening of the enclosure (e.g., its opening or closure). The motor
may be a step motor or a servomotor. The methods, systems and/or
the apparatus described herein may comprise a piston. The piston
may be a trunk, crosshead, slipper, or deflector piston.
[0214] In some embodiments, the 3D printer comprises one or more
nozzles. The systems and/or the apparatus described herein may
comprise at least one nozzle. The nozzle may be regulated according
to at least one input from at least one sensor. The nozzle may be
controlled automatically or manually. The controller may control
the nozzle. The nozzle may include jet (e.g., gas jet) nozzle, high
velocity nozzle, propelling nozzle, magnetic nozzle, spray nozzle,
vacuum nozzle, or shaping nozzle (e.g., a die). The nozzle can be a
convergent or a divergent nozzle. The spray nozzle may comprise an
atomizer nozzle, an air-aspirating nozzle, or a swirl nozzle.
[0215] In some embodiments, the 3D printer comprises one or more
pumps. The systems and/or the apparatus described herein may
comprise at least one pump. The pump may be regulated according to
at least one input from at least one sensor. The pump may be
controlled automatically or manually. The controller may control
the pump. The one or more pumps may comprise a positive
displacement pump. The positive displacement pump may comprise
rotary-type positive displacement pump, reciprocating-type positive
displacement pump, or linear-type positive displacement pump. The
positive displacement pump may comprise rotary lobe pump,
progressive cavity pump, rotary gear pump, piston pump, diaphragm
pump, screw pump, gear pump, hydraulic pump, rotary vane pump,
regenerative (peripheral) pump, peristaltic pump, rope pump or
flexible impeller. Rotary positive displacement pump may comprise
gear pump, screw pump, or rotary vane pump. The reciprocating pump
comprises plunger pump, diaphragm pump, piston pumps displacement
pumps, or radial piston pump. The pump may comprise a valve-less
pump, steam pump, gravity pump, eductor-jet pump, mixed-flow pump,
bellow pump, axial-flow pumps, radial-flow pump, velocity pump,
hydraulic ram pump, impulse pump, rope pump, compressed-air-powered
double-diaphragm pump, triplex-style plunger pump, plunger pump,
peristaltic pump, roots-type pumps, progressing cavity pump, screw
pump, or gear pump. In some examples, the systems and/or the
apparatus described herein include one or more vacuum pumps
selected from mechanical pumps, rotary vain pumps, turbomolecular
pumps, ion pumps, cryopumps, and diffusion pumps. The one or more
vacuum pumps may comprise Rotary vane pump, diaphragm pump, liquid
ring pump, piston pump, scroll pump, screw pump, Wankel pump,
external vane pump, roots blower, multistage Roots pump, Toepler
pump, or Lobe pump. The one or more vacuum pumps may comprise
momentum transfer pump, regenerative pump, entrapment pump, Venturi
vacuum pump, or team ejector.
[0216] In some embodiments, the 3D printer comprises a
communication technology. The systems, apparatuses, and/or parts
thereof may comprise Bluetooth technology. systems, apparatuses,
and/or parts thereof may comprise a communication port. The
communication port may be a serial port or a parallel port. The
communication port may be a Universal Serial Bus port (i.e., USB).
The systems, apparatuses, and/or parts thereof may comprise USB
ports. The USB can be micro or mini USB. The USB port may relate to
device classes comprising 00h, 01h, 02h, 03h, 05h, 06h, 07h, 08h,
09h, 0Ah, 0Bh, 0Dh, 0Eh, 0Fh, 10h, 11h, DCh, E0h, EFh, FEh, or FFh.
The surface identification mechanism may comprise a plug and/or a
socket (e.g., electrical, AC power, DC power). The systems,
apparatuses, and/or parts thereof may comprise an adapter (e.g., AC
and/or DC power adapter). The systems, apparatuses, and/or parts
thereof may comprise a power connector. The power connector can be
an electrical power connector. The power connector may comprise a
magnetically attached power connector. The power connector can be a
dock connector. The connector can be a data and power connector.
The connector may comprise pins. The connector may comprise at
least 10, 15, 18, 20, 22, 24, 26, 28, 30, 40, 42, 45, 50, 55, 80,
or 100 pins.
[0217] In some embodiments, the 3D printer comprises a controller.
The controller may monitor and/or direct (e.g., physical)
alteration of the operating conditions of the apparatuses,
software, and/or methods described herein. The controller may be a
manual or a non-manual controller. The controller may be an
automatic controller. The controller may operate upon request. The
controller may be a programmable controller. The controller may be
programed. The controller may comprise a processing unit (e.g., CPU
or GPU). The controller may receive an input (e.g., from a sensor).
The controller may deliver an output. The controller may comprise
multiple controllers. The controller may receive multiple inputs.
The controller may generate multiple outputs. The controller may be
a single input single output controller (SISO) or a multiple input
multiple output controller (MIMO). The controller may interpret the
input signal received. The controller may acquire data from the one
or more sensors. Acquire may comprise receive or extract. The data
may comprise measurement, estimation, determination, generation, or
any combination thereof. The controller may comprise feedback
control. The controller may comprise feed-forward control. The
control may comprise on-off control, proportional control,
proportional-integral (PI) control, or
proportional-integral-derivative (PID) control. The control may
comprise open loop control, or closed loop control. The controller
may comprise closed loop control. The controller may comprise open
loop control. The controller may comprise a user interface. The
user interface may comprise a keyboard, keypad, mouse, touch
screen, microphone, speech recognition package, camera, imaging
system, or any combination thereof. The outputs may include a
display (e.g., screen), speaker, or printer. The controller may be
any controller (e.g., a controller used in 3D printing) such as,
for example, the controller disclosed in Provisional Patent
Application Ser. No. 62/252,330 that was filed on Nov. 6, 2015,
titled "APPARATUSES, SYSTEMS AND METHODS FOR THREE-DIMENSIONAL
PRINTING," or in Provisional Patent Application Ser. No. 62/325,402
that was filed on Apr. 20, 2016, titled "METHODS, SYSTEMS,
APPARATUSES, AND SOFTWARE FOR ACCURATE THREE-DIMENSIONAL PRINTING,"
both of which are incorporated herein by reference in their
entirety.
[0218] Control may comprise regulate, modulate, adjust, maintain,
alter, change, govern, manage, restrain, restrict, direct guide,
oversee, manage, preserve, sustain, restrain, temper, or vary.
[0219] In some embodiments, the methods, systems, software and/or
the apparatuses described herein comprise a control system. The
control system can be in communication with one or more energy
sources and/or energy (e.g., energy beams). The energy sources may
be of the same type or of different types. For example, the energy
sources can be both lasers, or a laser and an electron beam. For
example, the control system may be in communication with the first
energy and/or with the second energy. The control system may
regulate the one or more energies (e.g., energy beams). The control
system may regulate the energy supplied by the one or more energy
sources. For example, the control system may regulate the energy
supplied by a first energy beam and by a second energy beam, to the
pre-transformed material within the material bed. The control
system may regulate the position of the one or more energy beams.
For example, the control system may regulate the position of the
first energy beam and/or the position of the second energy
beam.
[0220] In some embodiments, a plurality of energy beams is used to
transform the pre-transformed material and for one or more 3D
objects. The plurality of energy beams may be staggered (e.g., in a
direction). The direction of may be along the direction of the gas
flow, or at an angle relative to the direction of flow. The angle
may be perpendicular, or an angle different than perpendicular. The
plurality of energy beam may comprise 2, 3, 4, 5, 6, 7, 8, 9, or
10. The plurality of energy beams may form an array. At least two
of the plurality of energy beams may be controlled independently of
each other. At least two of the plurality of energy beams may be
controlled in concert. At least two of the plurality of energy
beams may translate independently of each other. At least two of
the plurality of energy beams may translate in concert. At least
two of the plurality of energy beams may be controlled by the same
controller. At least two of the plurality of energy beams may be
controlled by different controllers.
[0221] In some embodiments, the 3D printing system comprises a
processor. The processor may be a processing unit. The controller
may comprise a processing unit. The processing unit may be central.
The processing unit may comprise a central processing unit (herein
"CPU"). The controllers or control mechanisms (e.g., comprising a
computer system) may be programmed to implement methods of the
disclosure. The processor (e.g., 3D printer processor) may be
programmed to implement methods of the disclosure. The controller
may control at least one component of the systems and/or
apparatuses disclosed herein. FIG. 4 is a schematic example of a
computer system 400 that is programmed or otherwise configured to
facilitate the formation of a 3D object according to the methods
provided herein. The computer system 400 can control (e.g., direct,
monitor, and/or regulate) various features of printing methods,
apparatuses and systems of the present disclosure, such as, for
example, control force, translation, heating, cooling and/or
maintaining the temperature of a powder bed, process parameters
(e.g., chamber pressure), scanning rate (e.g., of the energy beam
and/or the platform), scanning route of the energy source, position
and/or temperature of the cooling member(s), application of the
amount of energy emitted to a selected location, or any combination
thereof. The computer system 401 can be part of, or be in
communication with, a 3D printing system or apparatus. The computer
may be coupled to one or more mechanisms disclosed herein, and/or
any parts thereof. For example, the computer may be coupled to one
or more sensors, valves, switches, motors, pumps, scanners, optical
components, or any combination thereof.
[0222] The computer system 400 can include a processing unit 406
(also "processor," "computer" and "computer processor" used
herein). The computer system may include memory or memory location
402 (e.g., random-access memory, read-only memory, flash memory),
electronic storage unit 404 (e.g., hard disk), communication
interface 403 (e.g., network adapter) for communicating with one or
more other systems, and peripheral devices 405, such as cache,
other memory, data storage and/or electronic display adapters. The
memory 402, storage unit 404, interface 403, and peripheral devices
405 are in communication with the processing unit 406 through a
communication bus (solid lines), such as a motherboard. The storage
unit can be a data storage unit (or data repository) for storing
data. The computer system can be operatively coupled to a computer
network ("network") 401 with the aid of the communication
interface. The network can be the Internet, an internet and/or
extranet, or an intranet and/or extranet that is in communication
with the Internet. In some cases, the network is a
telecommunication and/or data network. The network can include one
or more computer servers, which can enable distributed computing,
such as cloud computing. The network, in some cases with the aid of
the computer system, can implement a peer-to-peer network, which
may enable devices coupled to the computer system to behave as a
client or a server.
[0223] The processing unit can execute a sequence of
machine-readable instructions, which can be embodied in a program
or software. The instructions may be stored in a memory location,
such as the memory 602. The instructions can be directed to the
processing unit, which can subsequently program or otherwise
configure the processing unit to implement methods of the present
disclosure. Examples of operations performed by the processing unit
can include fetch, decode, execute, and write back. The processing
unit may interpret and/or execute instructions. The processor may
include a microprocessor, a data processor, a central processing
unit (CPU), a graphical processing unit (GPU), a system-on-chip
(SOC), a co-processor, a network processor, an application specific
integrated circuit (ASIC), an application specific instruction-set
processor (ASIPs), a controller, a programmable logic device (PLD),
a chipset, a field programmable gate array (FPGA), or any
combination thereof. The processing unit can be part of a circuit,
such as an integrated circuit. One or more other components of the
system 600 can be included in the circuit.
[0224] In some embodiments, the storage unit 404 stores files, such
as drivers, libraries and saved programs. The storage unit can
store user data (e.g., user preferences and user programs). In some
cases, the computer system can include one or more additional data
storage units that are external to the computer system, such as
located on a remote server that is in communication with the
computer system through an intranet or the Internet.
[0225] In some embodiments, the 3D printer comprises communicating
through a network. The computer system can communicate with one or
more remote computer systems through a network. For instance, the
computer system can communicate with a remote computer system of a
user (e.g., operator). Examples of remote computer systems include
personal computers (e.g., portable PC), slate or tablet PC's (e.g.,
Apple.RTM. iPad, Samsung.RTM. Galaxy Tab), telephones, Smart phones
(e.g., Apple.RTM. iPhone, Android-enabled device, Blackberry.RTM.),
or personal digital assistants. A user (e.g., client) can access
the computer system via the network.
[0226] Methods as described herein can be implemented by way of
machine (e.g., computer processor) executable code stored on an
electronic storage location of the computer system, such as, for
example, on the memory 402 or electronic storage unit 404. The
machine executable or machine-readable code can be provided in the
form of software. During use, the processor 406 can execute the
code. In some cases, the code can be retrieved from the storage
unit and stored on the memory for ready access by the processor. In
some situations, the electronic storage unit can be precluded, and
machine-executable instructions are stored on memory.
[0227] The code can be pre-compiled and configured for use with a
machine have a processer adapted to execute the code, or can be
compiled during runtime. The code can be supplied in a programming
language that can be selected to enable the code to execute in a
pre-compiled or as-compiled fashion.
[0228] In some instances, the processing unit includes one or more
cores. The computer system may comprise a single core processor,
multi core processor, or a plurality of processors for parallel
processing. The processing unit may comprise one or more central
processing unit (CPU) and/or a graphic processing unit (GPU). The
multiple cores may be disposed in a physical unit (e.g., Central
Processing Unit, or Graphic Processing Unit). The processing unit
may include one or more processing units. The physical unit may be
a single physical unit. The physical unit may be a die. The
physical unit may comprise cache coherency circuitry. The multiple
cores may be disposed in close proximity. The physical unit may
comprise an integrated circuit chip. The integrated circuit chip
may comprise one or more transistors. The integrated circuit chip
may comprise at least about 0.2 billion transistors (BT), 0.5 BT, 1
BT, 2 BT, 3 BT, 5 BT, 6 BT, 7 BT, 8 BT, 9 BT, 10 BT, 15 BT, 20 BT,
25 BT, 30 BT, 40 BT, or 50 BT. The integrated circuit chip may
comprise at most about 7 BT, 8 BT, 9 BT, 10 BT, 15 BT, 20 BT, 25
BT, 30 BT, 40 BT, 50 BT, 70 BT, or 100 BT. The integrated circuit
chip may comprise any number of transistors between the
afore-mentioned numbers (e.g., from about 0.2 BT to about 100 BT,
from about 1 BT to about 8 BT, from about 8 BT to about 40 BT, or
from about 40 BT to about 100 BT). The integrated circuit chip may
have an area of at least about 50 mm.sup.2, 60 mm.sup.2, 70
mm.sup.2, 80 mm.sup.2, 90 mm.sup.2, 100 mm.sup.2, 200 mm.sup.2, 300
mm.sup.2, 400 mm.sup.2, 500 mm.sup.2, 600 mm.sup.2, 700 mm.sup.2,
or 800 mm.sup.2. The integrated circuit chip may have an area of at
most about 50 mm.sup.2, 60 mm.sup.2, 70 mm.sup.2, 80 mm.sup.2, 90
mm.sup.2, 100 mm.sup.2, 200 mm.sup.2, 300 mm.sup.2, 400 mm.sup.2,
500 mm.sup.2, 600 mm.sup.2, 700 mm.sup.2, or 800 mm.sup.2. The
integrated circuit chip may have an area of any value between the
afore-mentioned values (e.g., from about 50 mm.sup.2 to about 800
mm.sup.2, from about 50 mm.sup.2 to about 500 mm.sup.2, or from
about 500 mm.sup.2 to about 800 mm.sup.2). The close proximity may
allow substantial preservation of communication signals that travel
between the cores. The close proximity may diminish communication
signal degradation. A core as understood herein is a computing
component having independent central processing capabilities. The
computing system may comprise a multiplicity of cores, which may be
disposed on a single computing component. The multiplicity of cores
may include two or more independent central processing units. The
independent central processing units may constitute a unit that
read and execute program instructions. The independent central
processing units may constitute parallel processing units. The
parallel processing units may be cores and/or digital signal
processing slices (DSP slices). The multiplicity of cores can be
parallel cores. The multiplicity of DSP slices can be parallel DSP
slices. The multiplicity of cores and/or DSP slices can function in
parallel. The multiplicity of cores may include at least about 2,
10, 40, 100, 400, 1000, 2000, 3000, 4000, 5000, 6000, 7000, 8000,
9000, 10000, 11000, 12000, 13000, 14000 or 15000 cores. The
multiplicity of cores may include at most about 1000, 2000, 3000,
4000, 5000, 6000, 7000, 8000, 9000, 10000, 11000, 12000, 13000,
14000, 15000, 20000, 30000, or 40000 cores. The multiplicity of
cores may include cores of any number between the afore-mentioned
numbers (e.g., from about 2 to about 40000, from about 2 to about
400, from about 400 to about 4000, from about 2000 to about 4000,
from about 4000 to about 10000, from about 4000 to about 15000, or
from about 15000 to about 40000 cores). In some processors (e.g.,
FPGA), the cores may be equivalent to multiple digital signal
processor (DSP) slices (e.g., slices). The plurality of DSP slices
may be equal to any of plurality core values mentioned herein. The
processor may comprise low latency in data transfer (e.g., from one
core to another). Latency may refer to the time delay between the
cause and the effect of a physical change in the processor (e.g., a
signal). Latency may refer to the time elapsed from the source
(e.g., first core) sending a packet to the destination (e.g.,
second core) receiving it (also referred as two-point latency).
One-point latency may refer to the time elapsed from the source
(e.g., first core) sending a packet (e.g., signal) to the
destination (e.g., second core) receiving it, and the designation
sending a packet back to the source (e.g., the packet making a
round trip). The latency may be sufficiently low to allow a high
number of floating point operations per second (FLOPS). The number
of FLOPS may be at least about 0.1 Tera FLOPS (T-FLOPS), 0.2
T-FLOPS, 0.25 T-FLOPS, 0.5 T-FLOPS, 0.75 T-FLOPS, 1 T-FLOPS, 2
T-FLOPS, 3 T-FLOPS, 5 T-FLOPS, 6 T-FLOPS, 7 T-FLOPS, 8 T-FLOPS, 9
T-FLOPS, or 10 T-FLOPS. The number of flops may be at most about
0.2 T-FLOPS, 0.25 T-FLOPS, 0.5 T-FLOPS, 0.75 T-FLOPS, 1 T-FLOPS, 2
T-FLOPS, 3 T-FLOPS, 5 T-FLOPS, 6 T-FLOPS, 7 T-FLOPS, 8 T-FLOPS, 9
T-FLOPS, 10 T-FLOPS, 20 T-FLOPS, 30 T-FLOPS, 50 T-FLOPS, 100
T-FLOPS, 1 P-FLOPS, 2 P-FLOPS, 3 P-FLOPS, 4 P-FLOPS, 5 P-FLOPS, 10
P-FLOPS, 50 P-FLOPS, 100 P-FLOPS, 1 EXA-FLOP, 2 EXA-FLOPS or 10
EXA-FLOPS. The number of FLOPS may be any value between the
afore-mentioned values (e.g., from about 0.1 T-FLOP to about 10
EXA-FLOPS, from about 0.1 T-FLOPS to about 1 T-FLOPS, from about 1
T-FLOPS to about 4 T-FLOPS, from about 4 T-FLOPS to about 10
T-FLOPS, from about 1 T-FLOPS to about 10 T-FLOPS, or from about 10
T-FLOPS to about 30 T-FLOPS, from about 50 T-FLOPS to about 1
EXA-FLOP, or from about 0.1 T-FLOP to about 10 EXA-FLOPS). In some
processors (e.g., FPGA), the operations per second may be measured
as (e.g., Giga) multiply-accumulate operations per second (e.g.,
MACs or GMACs). The MACs value can be equal to any of the T-FLOPS
values mentioned herein measured as Tera-MACs (T-MACs) instead of
T-FLOPS respectively. The FLOPS can be measured according to a
benchmark. The benchmark may be a HPC Challenge Benchmark. The
benchmark may comprise mathematical operations (e.g., equation
calculation such as linear equations), graphical operations (e.g.,
rendering), or encryption/decryption benchmark. The benchmark may
comprise a High Performance UNPACK, matrix multiplication (e.g.,
DGEMM), sustained memory bandwidth to/from memory (e.g., STREAM),
array transposing rate measurement (e.g., PTRANS), Random-access,
rate of Fast Fourier Transform (e.g., on a large one-dimensional
vector using the generalized Cooley-Tukey algorithm), or
Communication Bandwidth and Latency (e.g., MPI-centric performance
measurements based on the effective bandwidth/latency benchmark).
UNPACK may refer to a software library for performing numerical
linear algebra on a digital computer. DGEMM may refer to double
precision general matrix multiplication. STREAM benchmark may refer
to a synthetic benchmark designed to measure sustainable memory
bandwidth (in MB/s) and a corresponding computation rate for four
simple vector kernels (Copy, Scale, Add and Triad). PTRANS
benchmark may refer to a rate measurement at which the system can
transpose a large array (global). MPI refers to Message Passing
Interface.
[0229] In some instances, the computer system includes
hyper-threading technology. The computer system may include a chip
processor with integrated transform, lighting, triangle setup,
triangle clipping, rendering engine, or any combination thereof.
The rendering engine may be capable of processing at least about 10
million polygons per second. The rendering engines may be capable
of processing at least about 10 million calculations per second. As
an example, the GPU may include a GPU by Nvidia, ATI Technologies,
S3 Graphics, Advanced Micro Devices (AMD), or Matrox. The
processing unit may be able to process algorithms comprising a
matrix or a vector. The core may comprise a complex instruction set
computing core (CISC), or reduced instruction set computing
(RISC).
[0230] In some instances, the computer system includes an
electronic chip that is reprogrammable (e.g., field programmable
gate array (FPGA)). For example, the FPGA may comprise Tabula,
Altera, or Xilinx FPGA. The electronic chips may comprise one or
more programmable logic blocks (e.g., an array). The logic blocks
may compute combinational functions, logic gates, or any
combination thereof. The computer system may include custom
hardware. The custom hardware may comprise an algorithm.
[0231] In some instances, the computer system includes configurable
computing, partially reconfigurable computing, reconfigurable
computing, or any combination thereof. The computer system may
include a FPGA. The computer system may include an integrated
circuit that performs the algorithm. For example, the
reconfigurable computing system may comprise FPGA, CPU, GPU, or
multi-core microprocessors. The reconfigurable computing system may
comprise a High-Performance Reconfigurable Computing architecture
(HPRC). The partially reconfigurable computing may include
module-based partial reconfiguration, or difference-based partial
reconfiguration. The FPGA may comprise configurable FPGA logic,
and/or fixed-function hardware comprising multipliers, memories,
microprocessor cores, first in-first out (FIFO) and/or error
correcting code (ECC) logic, digital signal processing (DSP)
blocks, peripheral Component interconnect express (PCI Express)
controllers, ethernet media access control (MAC) blocks, or
high-speed serial transceivers. DSP blocks can be DSP slices.
[0232] In some examples, the computing system includes an
integrated circuit. The computing system may include an integrated
circuit that performs the algorithm (e.g., control algorithm). The
physical unit (e.g., the cache coherency circuitry within) may have
a clock time of at least about 0.1 Gigabits per second (Gbit/s),
0.5 Gbit/s, 1 Gbit/s, 2 Gbit/s, 5 Gbit/s, 6 Gbit/s, 7 Gbit/s, 8
Gbit/s, 9 Gbit/s, 10 Gbit/s, or 50 Gbit/s. The physical unit may
have a clock time of any value between the afore-mentioned values
(e.g., from about 0.1 Gbit/s to about 50 Gbit/s, or from about 5
Gbit/s to about 10 Gbit/s). The physical unit may produce the
algorithm output in at most about 0.1 microsecond (.mu.s), 1 .mu.s,
10 .mu.s, 100 .mu.s, or 1 millisecond (ms). The physical unit may
produce the algorithm output in any time between the above
mentioned times (e.g., from about 0.1 .mu.s, to about 1 ms, from
about 0.1 .mu.s, to about 100 .mu.s, or from about 0.1 .mu.s to
about 10 .mu.s).
[0233] In some instances, the controller uses calculations, real
time measurements, or any combination thereof to regulate the
energy beam(s). The sensor (e.g., temperature and/or positional
sensor) may provide a signal (e.g., input for the controller and/or
processor) at a rate of at least about 0.1 KHz, 1 KHz, 10 KHz, 100
KHz, 1000 KHz, or 10000 KHz). The sensor may provide a signal at a
rate between any of the above-mentioned rates (e.g., from about 0.1
KHz to about 10000 KHz, from about 0.1 KHz to about 1000 KHz, or
from about 1000 KHz to about 10000 KHz). The memory bandwidth of
the processing unit may be at least about 1 gigabytes per second
(Gbytes/s), 10 Gbytes/s, 100 Gbytes/s, 200 Gbytes/s, 300 Gbytes/s,
400 Gbytes/s, 500 Gbytes/s, 600 Gbytes/s, 700 Gbytes/s, 800
Gbytes/s, 900 Gbytes/s, or 1000 Gbytes/s. The memory bandwidth of
the processing unit may be at most about 1 gigabyte per second
(Gbytes/s), 10 Gbytes/s, 100 Gbytes/s, 200 Gbytes/s, 300 Gbytes/s,
400 Gbytes/s, 500 Gbytes/s, 600 Gbytes/s, 700 Gbytes/s, 800
Gbytes/s, 900 Gbytes/s, or 1000 Gbytes/s. The memory bandwidth of
the processing unit may have any value between the afore-mentioned
values (e.g., from about 1 Gbytes/s to about 1000 Gbytes/s, from
about 100 Gbytes/s to about 500 Gbytes/s, from about 500 Gbytes/s
to about 1000 Gbytes/s, or from about 200 Gbytes/s to about 400
Gbytes/s). The sensor measurements may be real-time measurements.
The real time measurements may be conducted during the 3D printing
process. The real-time measurements may be in situ measurements in
the 3D printing system and/or apparatus. the real time measurements
may be during the formation of the 3D object. In some instances,
the processing unit may use the signal obtained from the at least
one sensor to provide a processing unit output, which output is
provided by the processing system at a speed of at most about 100
min, 50 min, 25 min, 15 min, 10 min, 5 min, 1 min, 0.5 min (i.e.,
30 sec), 15 sec, 10 sec, 5 sec, 1 sec, 0.5 sec, 0.25 sec, 0.2 sec,
0.1 sec, 80 milliseconds (msec), 50 msec, 10 msec, 5 msec, 1 msec,
80 microseconds (.mu.sec), 50 .mu.sec, 20 .mu.sec, 10 .mu.sec, 5
.mu.sec, or 1 .mu.sec. In some instances, the processing unit may
use the signal obtained from the at least one sensor to provide a
processing unit output, which output is provided at a speed of any
value between the afore-mentioned values (e.g., from about 100 min
to about 1 .mu.sec, from about 100 min to about 10 min, from about
10 min to about 1 min, from about 5 min to about 0.5 min, from
about 30 sec to about 0.1 sec, from about 0.1 sec to about 1 msec,
from about 80 msec to about 10 .mu.sec, from about 50 .mu.sec to
about 1 .mu.sec, from about 20 .mu.sec to about 1 .mu.sec, or from
about 10 .mu.sec to about 1 .mu.sec).
[0234] In some embodiments, the processing unit comprises an
output. The processing unit output may comprise an evaluation of
the temperature at a location, position at a location (e.g.,
vertical and/or horizontal), or a map of locations. The location
may be on the target surface. The map may comprise a topological or
temperature map. The temperature sensor may comprise a temperature
imaging device (e.g., IR imaging device).
[0235] In some embodiments, the processing unit receives a signal
from a sensor. The processing unit may use the signal obtained from
the at least one sensor in an algorithm that is used in controlling
the energy beam. The algorithm may comprise the path of the energy
beam. In some instances, the algorithm may be used to alter the
path of the energy beam on the target surface. The path may deviate
from a cross section of a model corresponding to the desired 3D
object. The processing unit may use the output in an algorithm that
is used in determining the manner in which a model of the desired
3D object may be sliced. The processing unit may use the signal
obtained from the at least one sensor in an algorithm that is used
to configure one or more parameters and/or apparatuses relating to
the 3D printing process. The parameters may comprise a
characteristic of the energy beam. The parameters may comprise
movement of the platform and/or material bed. The parameters may
comprise relative movement of the energy beam and the material bed.
In some instances, the energy beam, the platform (e.g., material
bed disposed on the platform), or both may translate. Alternatively
or additionally, the controller may use historical data for the
control. Alternatively or additionally, the processing unit may use
historical data in its one or more algorithms. The parameters may
comprise the height of the layer of powder material disposed in the
enclosure and/or the gap by which the cooling element (e.g., heat
sink) is separated from the target surface. The target surface may
be the exposed layer of the material bed.
[0236] Aspects of the systems, apparatuses, and/or methods provided
herein, such as the computer system, can be embodied in programming
(e.g., using a software). Various aspects of the technology may be
thought of as "product," "object," or "articles of manufacture"
typically in the form of machine (or processor) executable code
and/or associated data that is carried on or embodied in a type of
machine-readable medium. Machine-executable code can be stored on
an electronic storage unit, such memory (e.g., read-only memory,
random-access memory, flash memory) or a hard disk. The storage may
comprise non-volatile storage media. "Storage" type media can
include any or all of the tangible memory of the computers,
processors or the like, or associated modules thereof, such as
various semiconductor memories, tape drives, disk drives, external
drives, and the like, which may provide non-transitory storage at
any time for the software programming.
[0237] In some examples, the computer system comprises a memory.
The memory may comprise a random-access memory (RAM), dynamic
random access memory (DRAM), static random access memory (SRAM),
synchronous dynamic random access memory (SDRAM), ferroelectric
random access memory (FRAM), read only memory (ROM), programmable
read only memory (PROM), erasable programmable read only memory
(EPROM), electrically erasable programmable read only memory
(EEPROM), a flash memory, or any combination thereof. The flash
memory may comprise a negative-AND (NAND) or NOR logic gates. A
NAND gate (negative-AND) may be a logic gate which produces an
output which is false only if all its inputs are true. The output
of the NAND gate may be complement to that of the AND gate. The
storage may include a hard disk (e.g., a magnetic disk, an optical
disk, a magneto-optic disk, a solid-state disk, etc.), a compact
disc (CD), a digital versatile disc (DVD), a floppy disk, a
cartridge, a magnetic tape, and/or another type of
computer-readable medium, along with a corresponding drive.
[0238] All or portions of the software may at times be communicated
through the Internet or various other telecommunication networks.
Such communications, for example, may enable loading of the
software from one computer or processor into another, for example,
from a management server or host computer into the computer
platform of an application server. Thus, another type of media that
may bear the software elements includes optical, electrical and
electromagnetic waves, such as used across physical interfaces
between local devices, through wired and optical landline networks
and over various air-links. The physical elements that carry such
waves, such as wired or wireless links, optical links, or the like,
also may be considered as media bearing the software. As used
herein, unless restricted to non-transitory, tangible "storage"
media, terms such as computer or machine "readable medium" refer to
any medium that participates in providing instructions to a
processor for execution.
[0239] Hence, a machine-readable medium, such as
computer-executable code, may take many forms, including but not
limited to, a tangible storage medium, a carrier wave medium, or
physical transmission medium. Non-volatile storage media include,
for example, optical or magnetic disks, such as any of the storage
devices in any computer(s) or the like, such as may be used to
implement the databases. Volatile storage media can include dynamic
memory, such as main memory of such a computer platform. Tangible
transmission media can include coaxial cables, wire (e.g., copper
wire), and/or fiber optics, including the wires that comprise a bus
within a computer system. Carrier-wave transmission media may take
the form of electric or electromagnetic signals, or acoustic or
light waves such as those generated during radio frequency (RF) and
infrared (IR) data communications. Common forms of
computer-readable media therefore include for example: a floppy
disk, a flexible disk, hard disk, magnetic tape, any other magnetic
medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch
cards paper tape, any other physical storage medium with patterns
of holes, a RAM, a ROM, a PROM and EPROM, a FLASH-EPROM, any other
memory chip or cartridge, a carrier wave transporting data or
instructions, cables or links transporting such a carrier wave, any
other medium from which a computer may read programming code and/or
data, or any combination thereof. The memory and/or storage may
comprise a storing device external to and/or removable from device,
such as a Universal Serial Bus (USB) memory stick, or/and a hard
disk. Many of these forms of computer readable media may be
involved in carrying one or more sequences of one or more
instructions to a processor for execution.
[0240] In some instances, the computer system comprises an
electronic display. The computer system can include or be in
communication with an electronic display that comprises a user
interface (UI) for providing, for example, a model design or
graphical representation of a 3D object to be printed. Examples of
UI's include, without limitation, a graphical user interface (GUI)
and web-based user interface. The computer system can monitor
and/or control various aspects of the 3D printing system. The
control may be manual and/or programmed. The control may rely on
feedback mechanisms (e.g., from the one or more sensors). The
control may rely on historical data. The feedback mechanism may be
pre-programmed. The feedback mechanisms may rely on input from
sensors (described herein) that are connected to the control unit
(i.e., control system or control mechanism e.g., computer) and/or
processing unit. The computer system may store historical data
concerning various aspects of the operation of the 3D printing
system. The historical data may be retrieved at predetermined times
and/or at a whim. The historical data may be accessed by an
operator and/or by a user. The historical, sensor, and/or operative
data may be provided in an output unit such as a display unit. The
output unit (e.g., monitor) may output various parameters of the 3D
printing system (as described herein) in real time or in a delayed
time. The output unit may output the current 3D printed object, the
ordered 3D printed object, or both. The output unit may output the
printing progress of the 3D printed object. The output unit may
output at least one of the total time, time remaining, and time
expanded on printing the 3D object. The output unit may output
(e.g., display, voice, and/or print) the status of sensors, their
reading, and/or time for their calibration or maintenance. The
output unit may output the type of material(s) used and various
characteristics of the material(s) such as temperature and
flowability of the pre-transformed material. The output unit may
output the amount of oxygen, water, and pressure in the printing
chamber (i.e., the chamber where the 3D object is being printed).
The computer may generate a report comprising various parameters of
the 3D printing system, method, and or objects at predetermined
time(s), on a request (e.g., from an operator), and/or at a whim.
The output unit may comprise a screen, printer, or speaker. The
control system may provide a report. The report may comprise any
items recited as optionally output by the output unit.
[0241] In some instances, the system and/or apparatus described
herein (e.g., controller) and/or any of their components comprise
an output and/or an input device. The input device may comprise a
keyboard, touch pad, or microphone. The output device may be a
sensory output device. The output device may include a visual,
tactile, or audio device. The audio device may include a
loudspeaker. The visual output device may include a screen and/or a
printed hard copy (e.g., paper). The output device may include a
printer. The input device may include a camera, a microphone, a
keyboard, or a touch screen.
[0242] In some instances, the computer system includes a user
interface. The computer system can include, or be in communication
with, an electronic display unit that comprises a user interface
(UI) for providing, for example, a model design or graphical
representation of an object to be printed. Examples of UI's include
a graphical user interface (GUI) and web-based user interface. The
historical and/or operative data may be displayed on a display
unit. The computer system may store historical data concerning
various aspects of the operation of the cleaning system. The
historical data may be retrieved at predetermined times and/or at a
whim. The historical data may be accessed by an operator and/or by
a user. The display unit (e.g., monitor) may display various
parameters of the printing system (as described herein) in real
time or in a delayed time. The display unit may display the desired
printed 3D object (e.g., according to a model), the printed 3D
object, real time display of the 3D object as it is being printed,
or any combination thereof. The display unit may display the
cleaning progress of the object, or various aspects thereof. The
display unit may display at least one of the total time, time
remaining, and time expanded on the cleaned object during the
cleaning process. The display unit may display the status of
sensors, their reading, and/or time for their calibration or
maintenance. The display unit may display the type or types of
material used and various characteristics of the material or
materials such as temperature and flowability of the
pre-transformed material. The display unit may display the amount
of a certain gas in the chamber. The gas may comprise an oxidizing
gas (e.g., oxygen), hydrogen, water vapor, or any of the gasses
mentioned herein. The gas may comprise a reactive agent. The
display unit may display the pressure in the chamber. The computer
may generate a report comprising various parameters of the methods,
objects, apparatuses, or systems described herein. The report may
be generated at predetermined time(s), on a request (e.g., from an
operator) or at a whim.
[0243] Methods, apparatuses, and/or systems of the present
disclosure can be implemented by way of one or more algorithms. An
algorithm can be implemented by way of software upon execution by
one or more computer processors. For example, the processor can be
programmed to calculate the path of the energy beam and/or the
power per unit area emitted by the energy source (e.g., that should
be provided to the material bed in order to achieve the desired
result). Other control and/or algorithm examples may be found in
provisional patent application No. 62/325,402, which is
incorporated herein by reference in its entirety.
[0244] In some embodiments, the 3D printer comprises and/or
communicates with a multiplicity of processors. The processors may
form a network architecture. The 3D printer may comprise at least
one processor (referred herein as the "3D printer processor"). The
3D printer may comprise a plurality of processors. At least two of
the plurality of the 3D printer processors may interact with each
other. At times, at least two of the plurality of the 3D printer
processors may not interact with each other.
[0245] In some embodiments, a 3D printer processor interacts with
at least one processor that acts as a 3D printer interface (also
referred to herein as "machine interface processor"). The processor
(e.g., machine interface processor) may be stationary or mobile.
The processor may be a remote computer systems. The machine
interface one or more processors may be connected to at least one
3D printer processor. The connection may be through a wire (e.g.,
cable) or be wireless (e.g., via Bluetooth technology). The machine
interface may be hardwired to the 3D printer. The machine interface
may directly connect to the 3D printer (e.g., to the 3D printer
processor). The machine interface may indirectly connect to the 3D
printer (e.g., through a server, or through wireless
communication). The cable may comprise coaxial cable, shielded
twisted cable pair, unshielded twisted cable pair, structured cable
(e.g., used in structured cabling), or fiber-optic cable.
[0246] In some embodiments, the machine interface processor directs
3D print job production, 3D printer management, 3D printer
monitoring, or any combination thereof. The machine interface
processor may not be able to influence (e.g., direct, or be
involved in) pre-print or 3D printing process development. The
machine management may comprise controlling the 3D printer
controller (e.g., directly or indirectly). The printer controller
may direct start (e.g., initiation) of a 3D printing process,
stopping a 3D printing process, maintenance of the 3D printer,
clearing alarms (e.g., concerning safety features of the 3D
printer).
[0247] In some embodiments, the machine interface processor allows
monitoring of the 3D printing process (e.g., accessible remotely or
locally). The machine interface processor may allow viewing a log
of the 3D printing and status of the 3D printer at a certain time
(e.g., 3D printer snapshot). The machine interface processor may
allow to monitor one or more 3D printing parameters. The one or
more printing parameters monitored by the machine interface
processor can comprise 3D printer status (e.g., 3D printer is idle,
preparing to 3D print, 3D printing, maintenance, fault, or
offline), active 3D printing (e.g., including a build module
number), status and/or position of build module(s), status of build
module and processing chamber engagement, type and status of
pre-transformed material used in the 3D printing (e.g., amount of
pre-transformed material remaining in the reservoir), status of a
filter, atmosphere status (e.g., pressure, gas level(s)),
ventilator status, layer dispensing mechanism status (e.g.,
position, speed, rate of deposition, level of exposed layer of the
material bed), status of the optical system (e.g., optical window,
mirror), status of scanner, alarm (, boot log, status change,
safety events, motion control commands (e.g., of the energy beam,
or of the layer dispensing mechanism), or printed 3D object status
(e.g., what layer number is being printed),
[0248] In some embodiments, the machine interface processor allows
monitoring the 3D print job management. The 3D print job management
may comprise status of each build module (e.g., atmosphere
condition, position in the enclosure, position in a queue to go in
the enclosure, position in a queue to engage with the processing
chamber, position in queue for further processing, power levels of
the energy beam, type of pre-transformed material loaded, 3D
printing operation diagnostics, status of a filter. The machine
interface processor (e.g., output device thereof) may allow viewing
and/or editing any of the job management and/or one or more
printing parameters. The machine interface processor may show the
permission level given to the user (e.g., view, or edit). The
machine interface processor may allow viewing and/or assigning a
certain 3D object to a particular build module, prioritize 3D
objects to be printed, pause 3D objects during 3D printing, delete
3D objects to be printed, select a certain 3D printer for a
particular 3D printing job, insert and/or edit considerations for
restarting a 3D printing job that was removed from 3D printer. The
machine interface processor may allow initiating, pausing, and/or
stopping a 3D printing job. The machine interface processor may
output message notification (e.g., alarm), log (e.g., other than
Excursion log or other default log), or any combination
thereof.
[0249] In some embodiments, the 3D printer interacts with at least
one server (e.g., print server). The 3D print server may be
separate or interrelated in the 3D printer. One or more users may
interact with the one or more 3D printing processors through one or
more user processors (e.g., respectively). The interaction may be
in parallel and/or sequentially. The users may be clients. The
users may belong to entities that desire a 3D object to be printed,
or entities who prepare the 3D object printing instructions. The
one or more users may interact with the 3D printer (e.g., through
the one or more processors of the 3D printer) directly and/or
indirectly. Indirect interaction may be through the server. One or
more users may be able to monitor one or more aspects of the 3D
printing process. One or more users can monitor aspects of the 3D
printing process through at least one connection (e.g., network
connection). For example, one or more users can monitor aspects of
the printing process through direct or indirect connection. Direct
connection may be using a local area network (LAN), and/or a wide
area network (WAN). The network may interconnect computers within a
limited area (e.g., a building, campus, neighborhood). The limited
area network may comprise Ethernet or Wi-Fi. The network may have
its network equipment and interconnects locally managed. The
network may cover a larger geographic distance than the limited
area. The network may use telecommunication circuits and/or
internet links. The network may comprise Internet Area Network
(IAN), and/or the public switched telephone network (PSTN). The
communication may comprise web communication. The aspect of the 3D
printing process may comprise a 3D printing parameter, machine
status, or sensor status. The 3D printing parameter may comprise
hatch strategy, energy beam power, energy beam speed, energy beam
focus, thickness of a layer (e.g., of hardened material or of
pre-transformed material).
[0250] In some embodiments, a user develops at least one 3D
printing instruction and directs the 3D printer (e.g., through
communication with the 3D printer processor) to print in a desired
manner according to the developed at least one 3D printing
instruction. A user may or may not be able to control (e.g.,
locally or remotely) the 3D printer controller. For example, a
client may not be able to control the 3D printing controller (e.g.,
maintenance of the 3D printer).
[0251] In some embodiments, the user (e.g., other than a client)
processor may use real-time and/or historical 3D printing data. The
3D printing data may comprise metrology data, or temperature data.
The user processor may comprise quality control. The quality
control may use a statistical method (e.g., statistical process
control (SPC)). The user processor may log excursion log, report
when a signal deviates from the nominal level, or any combination
thereof. The user processor may generate a configurable response.
The configurable response may comprise a print/pause/stop command
(e.g., automatically) to the 3D printer (e.g., to the 3D printing
processor). The configurable response may be based on a user
defined parameter, threshold, or any combination thereof. The
configurable response may result in a user defined action. The user
processor may control the 3D printing process and ensure that it
operates at its full potential. For example, at its full potential,
the 3D printing process may make a maximum number of 3D object with
a minimum of waste and/or 3D printer down time. The SPC may
comprise a control chart, design of experiments, and/or focus on
continuous improvement.
[0252] In some embodiments, the fundamental length scale (e.g., the
diameter, spherical equivalent diameter, diameter of a bounding
circle, or largest of height, width, depth, and length; abbreviated
herein as "FLS") of the printed 3D object or a portion thereof can
be at least about 50 micrometers (.mu.m), 80 .mu.m, 100 .mu.m, 120
.mu.m, 150 .mu.m, 170 .mu.m, 200 .mu.m, 230 .mu.m, 250 .mu.m, 270
.mu.m, 300 .mu.m, 400 .mu.m, 500 .mu.m, 600 .mu.m, 700 .mu.m, 800
.mu.m, 1 mm, 1.5 mm, 2 mm, 3 mm, 5 mm, 1 cm, 1.5 cm, 2 cm, 10 cm,
20 cm, 30 cm, 40 cm, 50 cm, 60 cm, 70 cm, 80 cm, 90 cm, 1 m, 2 m, 3
m, 4 m, 5 m, 10 m, 50 m, 80 m, or 100 m. The FLS of the printed 3D
object or a portion thereof can be at most about 150 .mu.m, 170
.mu.m, 200 .mu.m, 230 .mu.m, 250 .mu.m, 270 .mu.m, 300 .mu.m, 400
.mu.m, 500 .mu.m, 600 .mu.m, 700 .mu.m, 800 .mu.m, 1 mm, 1.5 mm, 2
mm, 3 mm, 5 mm, 1 cm, 1.5 cm, 2 cm, 10 cm, 20 cm, 30 cm, 40 cm, 50
cm, 60 cm, 70 cm, 80 cm, 90 cm, 1 m, 2 m, 3 m, 4 m, 5 m, 10 m, 50
m, 80 m, 100 m, 500 m, or 1000 m. The FLS of the printed 3D object
or a portion thereof can any value between the afore-mentioned
values (e.g., from about 50 .mu.m to about 1000 m, from about 500
.mu.m to about 100 m, from about 50 .mu.m to about 50 cm, or from
about 50 cm to about 1000 m). In some cases, the FLS of the printed
3D object or a portion thereof may be in between any of the
afore-mentioned FLS values. The portion of the 3D object may be a
heated portion or disposed portion (e.g., tile).
[0253] In some embodiments, the layer of pre-transformed material
(e.g., powder) is of a predetermined height (thickness). The layer
of pre-transformed material can comprise the material prior to its
transformation in the 3D printing process. The layer of
pre-transformed material may have an upper surface that is
substantially flat, leveled, or smooth. In some instances, the
layer of pre-transformed material may have an upper surface that is
not flat, leveled, or smooth. The layer of pre-transformed material
may have an upper surface that is corrugated or uneven. The layer
of pre-transformed material may have an average or mean (e.g.,
pre-determined) height. The height of the layer of pre-transformed
material (e.g., powder) may be at least about 5 micrometers
(.mu.m), 10 .mu.m, 20 .mu.m, 30 .mu.m, 40 .mu.m, 50 .mu.m, 60
.mu.m, 70 .mu.m, 80 .mu.m, 90 .mu.m, 100 .mu.m, 200 .mu.m, 300
.mu.m, 400 .mu.m, 500 .mu.m, 600 .mu.m, 700 .mu.m, 800 .mu.m, 900
.mu.m, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm,
20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200
mm, 300 mm, 400 mm, 500 mm, 600 mm, 700 mm, 800 mm, 900 mm, or 1000
mm. The height of the layer of pre-transformed material may be at
most about 5 micrometers (.mu.m), 10 .mu.m, 20 .mu.m, 30 .mu.m, 40
.mu.m, 50 .mu.m, 60 .mu.m, 70 .mu.m, 80 .mu.m, 90 .mu.m, 100 .mu.m,
200 .mu.m, 300 .mu.m, 400 .mu.m, 500 .mu.m, 600 .mu.m, 700 .mu.m,
800 .mu.m, 900 .mu.m, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8
mm, 9 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm,
90 mm, 100 mm, 200 mm, 300 mm, 400 mm, 500 mm, 600 mm, 700 mm, 800
mm, 900 mm, or 1000 mm. The height of the layer of pre-transformed
material may be any number between the afore-mentioned heights
(e.g., from about 5 .mu.m to about 1000 mm, from about 5 .mu.m to
about 1 mm, from about 25 .mu.m to about 1 mm, or from about 1 mm
to about 1000 mm). The "height" of the layer of material (e.g.,
powder) may at times be referred to as the "thickness" of the layer
of material. In some instances, the layer of hardened material may
be a sheet of metal. The layer of hardened material may be
fabricated using a 3D manufacturing methodology. Occasionally, the
first layer of hardened material may be thicker than a subsequent
layer of hardened material. The first layer of hardened material
may be at least about 1.1 times, 1.2 times, 1.4 times, 1.6 times,
1.8 times, 2 times, 4 times, 6 times, 8 times, 10 times, 20 times,
30 times, 50 times, 100 times, 500 times, 1000 times, or thicker
(higher) than the average (or mean) thickness of a subsequent layer
of hardened material, the average thickens of an average subsequent
layer of hardened material, or the average thickness of any of the
subsequent layers of hardened material. The very first layer of
hardened material formed in the material bed by 3D printing may be
referred herein as the "bottom skin" layer.
[0254] In some instances, one or more intervening layers separate
adjacent components from one another. For example, the one or more
intervening layers can have a thickness of at most about 10
micrometers ("microns"), 1 micron, 500 nanometers ("nm"), 100 nm,
50 nm, 10 nm, or 1 nm. For example, the one or more intervening
layers can have a thickness of at least about 10 micrometers
("microns"), 1 micron, 500 nanometers ("nm"), 100 nm, 50 nm, 10 nm,
or 1 nm. In an example, a first layer is adjacent to a second layer
when the first layer is in direct contact with the second layer. In
another example, a first layer is adjacent to a second layer when
the first layer is separated from the second layer by a third
layer. In some instances, adjacent to may be `above` or `below.`
Below can be in the direction of the gravitational force or towards
the platform. Above can be in the direction opposite to the
gravitational force or away from the platform.
[0255] In some embodiments, a projected energy beam heats a portion
of the material bed. The projected energy beam may irradiate a
portion of the material bed. The heat or irradiation of the portion
of the material bed may generate debris (e.g., metal vapor, molten
metal, plasma, etc.). The debris may be disposed in the enclosure
(e.g., processing chamber). For example, the debris may be disposed
in the atmosphere of the enclosure). For example, the debris may be
disposed on one or more components within the enclosure. For
example, the debris may be disposed on one or more internal
surfaces (e.g., walls or optical window) of the enclosure. For
example, the debris may float within the enclosure atmosphere. The
debris (e.g., accumulation thereof) may cause damage to various
components of the 3D printing system (e.g., the optical window).
The enclosure may comprise a gas flow (e.g., mechanism) that allows
displacement (e.g., removal) of the debris from a position in the
enclosure atmosphere (e.g., from the entire enclosure
atmosphere).
[0256] In some embodiments, the gas flow mechanism (also referred
to herein as "gas flow director," "gas flow manager," "gas flow
management system," or "gas flow management arrangement") comprises
structures that at least partially dictate the flowing of gas
across the (e.g., entire) enclosure and/or a portion of the
enclosure. The gas flow mechanism can be used to at least partially
control a characteristic of gas flow adjacent (e.g., over) the
target surface and/or the platform. Over the target surface may
comprise at most 2 cm, 5 cm, 10 cm, or 20 cm above the target
surface (e.g., the exposed surface of the material bed). Target
surface may refer to a surface that is a radiation target for the
energy beam. The gas flow mechanism can include a gas inlet portion
that at least partially controls the flow of gas entering into the
enclosure. The gas flow mechanism can include a gas outlet portion
that at least partially controls the flow of gas exiting the
enclosure. The gas flow mechanism can be used to at least partially
control a characteristic of gas flow adjacent to or within a
recessed portion of the enclosure (e.g., to purge the recessed
portion). The gas flow director can include the gas inlet portion,
the gas outlet portion, features for purging a recessed portion of
the enclosure, or any suitable combination thereof. The recessed
portion may be at the ceiling of the enclosure. The recessed
portion may be disposed at a wall of the enclosure opposing to the
target surface. The gas may comprise an inert gas (e.g., nitrogen
and/or argon). The gas may flow in bulk. The gas may flow in one or
more streams. The gas may comprise a non-reacting (e.g., inert)
gas. The gas may comprise an reactive agent depleted gas and/or
water depleted gas. The flow of the gas may comprise flowing across
at least a portion of the height (e.g., Y axis. See FIG. 8) of the
enclosure. For example, the flow of the gas may comprise flowing
across the entire height of the enclosure. The flow of the gas may
comprise flowing across at least a portion of the depth (e.g., Z
axis. See FIG. 8) of the enclosure. For example, the flow of the
gas may comprise flowing across the entire depth of the enclosure.
The flow of the gas may comprise flowing across at least a portion
of the width (e.g., X axis. See FIG. 8) of the enclosure (e.g.,
also referred herein as the length of the enclosure). For example,
the flow of the gas may comprise flowing across the entire width of
the enclosure. The flow of gas may comprise flowing onto an
internal surface of the optical window (e.g., facing the exposed
surface of the material bed, e.g., FIG. 15, 1543). The area
adjacent to the optical window may comprise one or more slots
(e.g., a slot per optical window, or a single slot for all optical
windows, or dispersed multiple slots across one or more optical
windows), one or more channels, or a combination thereof. The flow
of gas may comprise flowing through the one or more slots,
channels, or a combination thereof, on to the internal surface of
the optical window. The slot and/or channel may facilitate
directing the flow of gas onto the internal surface of the optical
window (e.g., 1543). For example, the gas flow may be optionally
evacuated from an area adjacent (e.g., directly adjacent) to the
one or more optical windows (e.g., from the 1541 side to the 1542
side of the optical window 1515). The flow of gas may reduce the
amount of (e.g., prevent) powder, soot, and/or debris from adhering
to the internal surface (e.g., 1543) of the one or more optical
windows. The flow of gas may reduce the amount of (e.g., prevent)
powder, soot, and/or debris from obstructing an optical path of the
energy beam (e.g., 1501) that travels from the optical window to
the exposed surface of the material bed (e.g., 1504). The flow of
gas may be (e.g., substantially) lateral. The flow of gas may be
(e.g., substantially) horizontal. The gas may flow along and/or
towards the one or more optical windows. The gas may flow in a
plurality of gas streams (e.g., FIG. 16, 1635). The gas streams may
be spread across at least a portion of the (e.g., entire) height
and/or depth of the enclosure. The gas streams may be evenly
spread. The gas streams may not be evenly spread (e.g., across at
least a portion of the enclosure height and/or depth). The gas
streams may flow across at least a portion of the enclosure height
and/or depth Across the enclosure, the gas streams may flow in the
same direction. The same direction may comprise from the gas-inlet
to the gas-outlet. The same direction may comprise from one edge of
the enclosure to the opposite end). The same direction may comprise
from the gas-inlet to the gas-outlet. The gas flow may flow
laterally across at least a portion of the (e.g., height and/or
depth of the) enclosure. The gas flow may flow laminarly across at
least a portion of the (e.g., height and/or depth of the)
enclosure. The at least a portion of the enclosure may comprise the
processing cone (e.g., FIG. 15, 1530). In one embodiment, the gas
streams may not flow in the same direction. In one embodiment, one
or more gas streams may flow in the same direction and one or more
gas streams may flow in the opposite direction. FIG. 16 shows an
example simulation of gas streams at different velocities across
the width and height area of the gas flow mechanism. The gas flow
(e.g., in the at least one stream) may comprise a laminar flow. The
gas flow may comprise flow in a constant velocity during at least a
portion of the 3D printing. For example, the gas flow may comprise
flow in a constant velocity during the operation of the energy beam
(e.g., during the transformation of at least a portion of the
material bed). Laminar flow may comprise fluid flow (e.g., gas
flow) in (e.g., substantially) parallel layers. The gas flow may
comprise flow in a varied velocity during at least a portion of the
3D printing. For example, the gas flow may comprise flow in a
varied velocity during the operation of the energy beam (e.g.,
during the transformation of at least a portion of the material
bed). The gas streams may comprise a turbulent flow. Turbulent flow
may comprise (e.g., random, and/or irregular) fluctuations in
pressure, magnitude, direction and/or flow velocity of the gas.
Turbulent flow may comprise a chaotic flow. In some embodiments,
the chaotic flow comprises circular, swirling, agitated, rough,
irregular, disordered, disorganized, cyclonic, spiraling, vortex,
or agitated movement of the gas. In some embodiments, the mixing
comprises laminar, vertical, horizontal, or angular movement. The
gas flow within at least two of the gas streams within the
enclosure may be of a different velocity and/or density. The gas
flow within at least two of the gas streams within the enclosure
may be of the same magnitude. The gas flow within at least two of
the gas streams within the enclosure may be of variable magnitude.
The gas flow (e.g., of at least one gas stream) within the
enclosure may be free of standing vortices. A standing vortex may
be described as a vortex in which the axis of fluid rotation
remains in (e.g., substantially) the same location, e.g., not
transmitted with the rest of the flow. Turbulent flow of gas within
the enclosure may generate a vortex that transmits with the rest of
the flow, thus generating a gas flow without standing vortices. The
gas flow mechanism may not comprise (i) recirculation of gas, (ii)
gas flow stagnation, or (iii) static vortices, within the
enclosure. For example, the gas flow mechanism may not comprise
recirculation of gas within the enclosure. The gas flow (e.g., in
the enclosure) may be continuous. Continuously may be during the
operation of the 3D printer (e.g., before, during and/or after the
3D printing or a portion thereof). The gas stream(s) may be altered
(e.g., reduced, or cease to flow) when the energy beam is not
operating (e.g., to transform at least a portion of the material
bed). Optionally, at least portion of the gas flow may be changed
before, during or after dispensing mechanism performs dispensing.
The alteration may be in velocity, gas stream trajectory, gas
content, pressure, humidity content, oxidizing gas content, gas
flow cross section (e.g., at full width half maximum). or any
combination thereof. The velocity of the gas (e.g., in the
enclosure) can be at least about 0.1 m/s, 0.2 m/s, 0.3 m/s, 0.5
m/s, 0.7 m/s, 0.8 m/s, 1 m/s, 2 m/s, 5 m/s, 10 m/s, 15 m/s, 20 m/s,
30 m/s or 50 m/s. The velocity of gas can be at most about 0.1 m/s,
0.2 m/s, 0.3 m/s, 0.5 m/s, 0.7 m/s, 0.8 m/s, 1 m/s, 2 m/s, 5 m/s,
10 m/s, 15 m/s, 20 m/s, 30 m/s or 50 m/s. The velocity of the gas
(e.g., in the enclosure) can be between any of the afore-mentioned
values (e.g., from about 0.1 m/s to about 50 m/s, from about 0.1
m/s to about 1 m/s, from about 2 m/s to about 20 m/s, from about 30
m/s to about 50 m/s, or from about 0.7 m/s to about 1 m/s). The
velocity of the gas can be during at least a portion of the 3D
printing. The velocity of the gas can refer to its flow velocity
along any one of its components. The velocity of the gas can have a
component along the width of the chamber (X direction, FIG. 8). The
velocity of the gas can have a component along the height of the
chamber (Y direction, FIG. 8). The velocity of the gas can have a
component along the depth of the chamber (Z direction, FIG. 8).
[0257] In an example, a layer dispensing mechanism is reversibly
parked in an isolatable ancillary chamber when it does not perform
a layer dispensing operation. The energy beam may be projected on
the material bed when the layer dispensing mechanism resides within
the ancillary chamber (e.g., isolated from the processing chamber),
and the gas flow may continue during operation of energy beam (i.e.
lasing). The gas stream(s) may be altered (e.g., reduced, or cease
to flow) when the layer dispensing mechanism performs a dispensing
of a layer of material (e.g., and exits the ancillary chamber). The
gas stream(s) may continue to flow when the layer dispensing
mechanism performs a dispensing of a layer of material. Operation
of the energy beam may comprise a dwell time of the energy
beam.
[0258] In some instances, the gas flow mechanism comprises laminar
a flow at least within the (e.g., atmospheric) area of the
processing cone (e.g., above the platform, FIG. 15, 1530). The gas
may flow in (e.g., substantial) at least two laminar streams while
in the processing cone area. For example, the gas may flow in
(e.g., substantially) laminar streams with in the processing cone.
Across the enclosure (e.g., FIG. 15, 1526) height and/or depth, the
gas streams may flow in the same direction (e.g., from one side of
the processing cone to the opposite side of the processing cone).
The flow across the depth and/or height of the processing cone may
comprise a lateral flow. The gas may flow in a smooth (e.g., and
continuous) manner at least within the processing cone area. The
gas flow at least in the processing cone (e.g., in the processing
chamber) may not comprise (i) recirculation of gas, (ii) gas flow
stagnation, or (iii) static vortices, at least within the
processing cone area. In the processing chamber, may comprise
substantially in the entire processing chamber. Substantially is
relative to the intended purpose of the 3D printer. For example,
substantially in the entire processing chamber may exclude a volume
of the processing chamber corner(s). The gas may flow from one side
of the processing chamber to the other side of the processing
chamber, which gas flow travels at least through the processing
cone, and/or has a flow velocity direction that is always
unidirectional (e.g., does not change in direction or becomes
stagnant). The gas flow from one side of the processing chamber to
the other side of the processing chamber. In some embodiments, the
gas flow travels at least through the processing cone, has a flow
velocity direction that is always positive (e.g., does not become
negative or zero). The magnitude and/or direction of the flow
velocity can differ along the depth (i.e., Z direction) or height
(i.e., Y direction) of the enclosure. The magnitude of the flow
velocity can differ along the width (i.e., X direction) of the
enclosure. In some examples, the magnitude of the gas flow velocity
along the depth, height and/or width of the enclosure may be (e.g.,
substantially) constant. In some examples, the direction of the gas
flow velocity along the depth, height and/or width of the enclosure
may be (e.g., substantially) constant. In some examples, the
magnitude of the gas flow velocity along the depth, height and/or
width of the enclosure may vary (e.g., linearly, or exponentially).
The variation may be a time variation (e.g., during the 3D
printing, such as during the operation of the energy beam). The
variation may be a special variation (e.g., along the width, depth,
and/or height of the enclosure). Along the enclosure comprises
along the processing cone.
[0259] In some instances, the phrase "at least within the
processing cone area of the enclosure" comprises at least within
the atmospheric area above the platform (e.g., FIG. 15, 1530) and
in the enclosure (e.g., FIG. 15, 1526). At least within the
processing cone area of the enclosure may be disposed in the
enclosure. In some instances, the enclosure may comprise a suction
mechanism comprising a reduced pressure (e.g., vacuum duct). The
low-pressure duct(s) may be disposed adjacent to the platform
and/or exposed surface of the material bed within the processing
cone area. The suction mechanism may at least remove a portion of
debris (e.g., particulate material). The suction mechanism may be
activated when the energy beam is and/or is not projected towards
the material bed. The suction mechanism may be activated before,
after, and/or during the 3D printing. The suction mechanism may be
activated during at least a portion of the 3D printing. During at
least a portion of the 3D printing may comprise during a
transformation of a portion of the material bed, during the layer
dispensing, or between the transformation and the layer dispensing.
The suction mechanism may be activated at a time when the gas
streams in the enclosure cease to flow.
[0260] In some examples, the gas flow mechanism comprises an inlet
portion (e.g., FIG. 8, 840, 842, FIG. 9, 940, FIG. 12, 1235, FIG.
13, 1330), which can also be referred to as an inlet portion, gas
inlet portion, gas inlet port, gas inlet portion, or other suitable
term. The inlet portion may be connected to a side wall of the
enclosure (e.g., FIG. 8, 873). The inlet portion (e.g., FIG. 12,
1235) may comprise one or more inlets (e.g., 1250). The side wall
may be an internal side wall (e.g. FIG. 9, 926). The side wall may
be a divider forming a processing chamber side wall (e.g., FIG. 12,
1236). The inlet portion may include one or more openings (e.g.,
FIG. 9, 955, FIG. 12, 1250, 1252, 1255, FIG. 11A, 1145, FIG. 11B,
1155) to facilitate gas flow into the enclosure (e.g., into the
inlet portion). In some embodiments, the inlet portion may be
separated from the processing chamber by an internal inlet (e.g.,
separation) wall (e.g., 1236). The aspect ratio of the internal
inlet wall (e.g., 926) relative to an inlet opening (e.g., 955) can
be at least about 500:1, 250:1, 200:1, 100:1, 50:1, 25:1 or 10:1.
The aspect ratio of the internal inlet wall (e.g., 926) relative to
an outlet opening (e.g., 955) can be at most about 500:1, 250:1,
200:1, 100:1, 50:1, 25:1 or 10:1. The aspect ratio of the internal
inlet wall relative to an inlet opening can be between any of the
afore-mentioned values (e.g., from about 500:1 to about 10:1, from
about 500:1 to about 100:1, from about 100:1 to about 50:1, or from
about 50:1 to about 10:1). In some embodiments, the inlet portion
is separated from the processing chamber by a filter (e.g., HEPA
filter). The filter may be one of the filters disclosed herein. In
some embodiments, the outlet portion (e.g., 1240) may be separated
from the processing chamber (e.g., 1226) by an internal outlet
(e.g., separation) wall (e.g., 1237). The internal outlet wall
and/or internal inlet wall may comprise an opening. The term
"opening" may refer to the internal inlet wall opening, internal
outlet wall opening, inlet opening, and/or outlet opening. Examples
of internal wall openings can be seen in the examples in FIGS.
7A-7B and FIGS. 10A-10D. The openings may be (e.g., reversibly)
coupled to at least one side wall of the inlet portion. For
example, one or more openings may be coupled to the same side wall.
The opening may be gas inlet opening that facilitate gas flow into
the enclosure. The opening may be gas outlet opening that
facilitate gas flow out of the enclosure. The multiple openings on
the wall may be uniformly spaced horizontally, vertically and/or at
an angle (e.g., 1250, 1252 and 1255). The multiple openings may not
be uniformly spaced. The openings may run across the entire wall of
the enclosure (e.g., height and/or depth thereof). For example, the
openings may occupy a percentage of the enclosure height and/or
depth (e.g., FIG. 10A). The percentage may be at least about 50%,
60%, 70%, 80%, 90%, 95%, 98% or 99% of the enclosure height and/or
depth. The openings may run across any number between the
afore-mentioned heights and/or depths of the enclosure wall (e.g.,
from about 50% to about 99%, from about 50% to about 70%, from
about 70% to about 90%, or from about 90% to about 99%). The
openings may be evenly or non-evenly spaced. For example, a greater
concentration of openings may reside closer to the platform and/or
exposed surface of the material bed (e.g., FIG. 7A, 751). For
example, a lower concentration of openings may reside closer to the
ceiling of the enclosure (e.g., FIG. 7A, 752). For example, a
greater concentration of passable openings may reside closer to the
platform and/or exposed surface of the material bed (e.g., FIG. 7B,
761). For example, a lower concentration of closed openings may
reside closer to the ceiling of the enclosure (e.g., FIG. 7B, 762).
In some examples, the openings may extend from an exposed surface
of the material bed and/or platform, to the optical window. In some
examples, the openings may extend from an exposed surface of the
material bed and/or platform, to at least 50%, 60%, 70%, 80%, 90%,
95%, 98%, or 99% height of the enclosure. The openings extend from
an exposed surface of the material bed and/or platform by any
number between the afore-mentioned examples (e.g., from about 50%
to about 99%, from about 50% to about 70%, from about 70% to about
90%, or from about 90% to about 99%). The opening may be oval
(e.g., FIG. 10D, 1040). For example, the opening may be circular
(e.g., FIG. 10A, 1010). The opening may be pipe shaped. A cross
section of the opening may be any geometrical shape (e.g.,
hexagonal, rectangular, square, circular or triangle). A cross
section of the openings may be random (e.g., FIG. 10D, 1041). An
opening may be a slit (e.g., FIG. 7C, 711). The openings may
comprise an array of openings (e.g., FIG. 10A). The openings may
comprise a single file of openings (e.g., FIG. 10C, including
opening 1030). The cross section of the openings may change its
shape before, during, and/or after the 3D printing (or a portion
thereof, e.g., during the operation of the energy beam). The
cross-sectional shape of the openings can be controlled (e.g.,
manually and/or by a controller). The cross-sectional shape of the
openings may be altered by the controller. The alteration may
comprise an electronic, magnetic, temperature, audio, or optical
signal. The alteration may be induced electronically, magnetically,
by temperature alteration, audibly, optically, or by any
combination thereof. The alteration of at least two openings (e.g.,
within the array of openings) may be collectively (e.g.,
simultaneously or sequentially) controlled. The alteration of at
least two openings (e.g., within the array of openings) may be
separately (e.g., individually) controlled. The percentage of void
forming the opening may be controlled before, during, and/or after
the 3D printing (or a portion thereof, e.g., during the operation
of the energy beam). For example, at least an opening may be closed
(e.g., a line of openings, a plurality of opening, or the entire
array). FIG. 10D shows an example of a passable opening 1040 and a
closed opening 1042. The opening may have any opening values
disclosed herein. In some examples, the opening can comprise sizes
of at least about 0.1 millimeter (mm), 0.2 mm, 0.5 mm, 1 mm, 2 mm,
5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90
mm, or 100 mm. The opening can comprise sizes of at most about 0.1
millimeter (mm), 0.2 mm, 0.5 mm, 1 mm, 2 mm, 5 mm, 10 mm, 20 mm, 30
mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, or 100 mm. The
opening can comprise sizes between any of the opening sizes
disclosed herein. For example, the opening can comprise sizes from
about 0.1 mm to about 100 mm, from about 5 mm to about 50 mm, or
from about 50 mm to about 100 mm.
[0261] In some examples, the inlet and/or outlet opening comprises
a valve. In some examples, at least two openings may share the same
valve. In some examples, at least two openings may have different
valves. The valve may control the flow of gas through the inlet
opening. Control the flow may comprise flow velocity, pressure, gas
content (e.g., oxidizing gas content), humidity content, gas make
up. The valve may be a mechanical, electrical, electro-mechanical,
manually operable, controlled, or an automated valve. The valve may
comprise a pressure relief, pressure release, pressure safety,
safety relief, pilot-operated relief, low pressure safety, vacuum
pressure safety, low and vacuum pressure safety, pressure vacuum
release, snap acting, or a modulating valve. The valve may comply
with the legal industry standards presiding the jurisdiction. The
inlet and/or outlet portion may comprise one or more ledges. The
ledge may control the amount and/or direction of gas flow into the
enclosure (e.g., processing chamber). The ledge may be pivotable
(e.g., along a set of points on the edge) before, after, and/or
during the 3D printing (or a portion thereof. For example, during
the operation of the energy beam). The ledge may be movable before,
after, and/or during the 3D printing (or a portion thereof. E.g.,
during the operation of the energy beam). The ledge may be
retractable before, after, and/or during the 3D printing (or a
portion thereof. E.g., during the operation of the energy beam).
The ledge may be controllable manually and/or automatically (e.g.,
using a controller). The control may be before, after, and/or
during the 3D printing (or a portion thereof. E.g., during the
operation of the energy beam). The amount and/or velocity of gas
conveyed by the ledge may be controllable (e.g., in real time). The
ledge may be closable so that a reduced amount of gas will flow
into the enclosure (e.g., no gas will flow into the enclosure). The
ledge may extend from one edge of the inlet and/or outlet opening
space to the opposite edge of the inlet and/or outlet opening space
respectively. FIG. 12, 1240 shows an example of an outlet opening
space. The ledge may protrude from the gas inlets (e.g., 1250)
towards the divider comprising the opening(s) (e.g., 1236). The
ledge may protrude from the divider comprising the opening(s)
(e.g., 1236) towards the gas outlet (e.g., 1246).
[0262] In some examples, the inlet portion comprises a perforated
plate (a mesh, screen, e.g., FIG. 10A, FIG. 10C, FIG. 10D). The
internal inlet wall and/or internal outlet wall may comprise the
perforated plate. In some instances, the inlet portion may comprise
more than one perforated plates. The multiple perforated plates may
be stacked (e.g., vertically, horizontally, and/or at an angle).
The multiple perforated plates may be stacked in parallel to each
other. The perforated plate may comprise one or more perforations
(e.g., FIG. 10A, 1010). The perforation may be an opening (e.g., as
disclosed herein). The perforations may be uniformly spread across
at least a portion (e.g., the entire) perforated plate. FIG. 10A
shows an example of uniform perforation spread across the entire
perforated plate. FIG. 7A shows an example of uniform perforation
spread across a portion of the perforated plate (e.g. line numbers
1 to 3) The perforated plate may comprise a single file (e.g., row)
of perforations (e.g., FIG. 10C). At times, the size of the
perforations in the plate may be uniform (e.g., FIG. 10A). At
times, the size of the perforations in the plate may not be uniform
(e.g., FIG. 10D, row number 5). At times, the angle of the
perforations in the plate may not be uniform (e.g., FIG. 10D, row
number 2). At times, the angle of the perforations in the plate may
not be uniform (e.g., FIG. 10D, row number 7 or 3). At times, the
pass-ability of the perforations in the plate may not be uniform
(e.g., FIG. 10D, row number 2, wherein a black perforation
designates a closed perforation, and a gray perforation represents
an open perforation). The size of the perforations may be
controlled (e.g., as described herein re openings). For example,
the perforations may be thermally controlled. The size of the
perforations may contract with increase in surface temperature. The
size of the perforations may expand with a decrease in temperature.
The size of the openings (e.g., perforations) may be altered to
control the amount and/or velocity of flow of gas through each
opening. Altered may comprise increasing and/or decreasing the
opening size.
[0263] In some examples, the inlet and/or outlet portion comprises
one or more ledges (e.g., FIG. 10B, 1020). The ledges may be
baffles. At times, the inlet and/or outlet portion may comprise a
perforated plate or a ledge. At times, the inlet and/or outlet
portion may comprise both a perforated plate and a ledge. The ledge
may be movable. For example, the ledge may be movable before,
during, and/or after the 3D printing. For example, the ledge may be
movable during a portion of the 3D printing. During a portion of
the 3D printing may comprise during the operation of the energy
beam, or during the formation of a layer of hardened material. The
ledge may be controlled manually and/or automatically. The ledge
may direct one or more streams of gas to flow in a certain
direction. The ledge may alter the amount and/or velocity of the
gas stream. For example, the ledge may (e.g., substantially)
prevent the gas flow through it by closing an opening. The ledge
may laterally extend from one edge of the intermediate wall to an
opposing wall away from the processing chamber. The opposing wall
may comprise an inlet or outlet opening. The ledge and/or opening
may be passive. The position (e.g., horizontal, vertical, and/or
angular) of the ledges may be controlled (e.g., during at least a
portion of the 3D printing). The position of the ledge may be
altered to control the amount, velocity, and/or direction of flow
of at least one gas through each ledge. Altered may comprise
reducing gas flow (e.g., preventing). Altered may comprise allowing
gas flow.
[0264] In some instances, the inlet portion comprises a geometric
shape (e.g., rectangular shape, square shape, circular shape, box
shape). FIG. 8 shows an example of inlet portions, e.g., 840, 842.
FIG. 12 and FIG. 13 show an example of an inlet portion, e.g.,
1235, 1335. The inlet portion may be aerodynamically shaped (e.g.,
wind tunnel shape, tubular shape, rain drop shape, rocket shape).
The aerodynamic shape may enable smooth flow of gas through the
inlet portion. The aerodynamic shape may prevent the formation of
standing vortices, cyclones, and/or stagnant gas. FIG. 9 shows an
example of an inlet portion having an aerodynamic shape 940. The
aerodynamic shape may initiate from at least one (e.g., narrow)
opening (e.g., FIG. 9, 955) distant from the processing chamber
(e.g., FIG. 9, 901). The acute angle of the average aerodynamic
shape plane (e.g., FIG. 8, 874) relative to the floor of the
processing chamber (e.g., 875, or the exposed surface of the
material bed 876) can be at least about 20.degree., 30.degree.,
40.degree., 42.degree., 45.degree., 50.degree., 60.degree.,
70.degree., or 80.degree.. The acute angle of the average
aerodynamic shape plane relative to the floor of the processing
chamber can be at most about, 20.degree., 30.degree., 40.degree.,
42.degree., 45.degree., 50.degree., 60.degree., 70.degree., or
80.degree.. The acute angle of the average aerodynamic shape plane
shape relative to the floor of the processing chamber can be
between any of the afore-mentioned values (e.g., from about
20.degree. to about 80.degree., from about 20.degree. to about
40.degree., from about 40.degree. to about 60.degree., or from
about 60.degree. to about 80.degree.). The aerodynamic shape may
comprise a pyramidal, or a conical 3D shape. The inlet portion may
comprise one or more baffles (e.g., FIG. 13, 1360). A baffle, as
understood herein, may be a device used to restrain and/or deflect
the flow of gas. The baffle may be placed after an inlet opening
(e.g., FIG. 13, 1360). The baffle may be placed within an inlet
portion (e.g., FIG. 13, 1360). The baffle may be placed at a
location within the processing chamber. The baffle may be placed at
a location within the enclosure (e.g., FIG. 9, 965, 970). There may
be one or more baffles within the enclosure. At least one surface
of the baffle may be smooth, or rough. The baffle may comprise
indentations. The indentations may form a pattern. The indentation
may facilitate directing the gas flow. The baffle may comprise one
or more openings (e.g., as disclosed herein). For example, the size
of the perforations may be uniform or non-uniform. For example, the
size of the perforations may be controlled. The baffle may be a
deflector. The deflector may be a gas (e.g., wind) deflector. The
deflector may aid in directing the glow of gas. The deflector may
redirect the flow of gas. The deflector may be a screen. The
deflector may be a shield.
[0265] In some instances, the gas flow mechanism comprises an
outlet portion (e.g., FIG. 8, 870, FIG. 9, 945, FIG. 12, 1245, FIG.
13, 1345), which can also be referred to as an outlet portion, gas
outlet port volume, gas outlet volume, gas outlet portion, or other
suitable term. The gas outlet portion may have similar structure
and/or apparatuses to the gas inlet portion. The outlet portion may
be connected (e.g., reversibly) to a side wall of the enclosure.
For example, the outlet portion may be connected (e.g., reversibly)
to a first side wall that opposes a second side wall that is
coupled to the inlet area. The outlet portion can include one or
more outlet openings (e.g., FIG. 9, 950). The one or more outlet
openings may be coupled (e.g., reversibly) to at least one side
wall of the outlet portion. The multiple openings may or may not be
uniformly spaced. The outlet openings may run across the entire
wall of the enclosure (e.g., horizontally, vertically, and/or at an
angle). For example, the outlet openings may occupy a percentage of
the enclosure height and/or depth. The percentage may be at least
about 50%, 60%, 70%, 80%, 90% or 95% of the enclosure height and/or
depth. The outlet openings may be evenly or non-evenly spaced. The
openings may run across any number between the afore-mentioned
heights and/or depths of the enclosure wall (e.g., from about 50%
to about 99%, from about 50% to about 70%, from about 70% to about
90%, or from about 90% to about 99%). For example, a greater
concentration of outlets may reside closer to the platform and/or
exposed surface of the material bed. For example, a lower
concentration of outlet openings may reside closer to the ceiling
of the enclosure. In some examples, the outlet openings may extend
from an exposed surface of the material bed and/or the platform to
the optical window. In some examples, the outlet openings may
extend from an exposed surface of the material bed and/or platform
to at least about 50%, 60%, 70%, 80%, 90% 95%, 98%, or 99% height
and/or depth of the enclosure. The openings extend from an exposed
surface of the material bed and/or platform by any number between
the afore-mentioned examples (e.g., from about 50% to about 99%,
from about 50% to about 70%, from about 70% to about 90%, or from
about 90% to about 99%). The outlet opening may be any opening
disclosed herein.
[0266] In some instances, the center of the inlet opening and/or
outlet opening are disposed in an enclosure wall (e.g., side wall,
e.g., FIG. 8, 873) in a position. That position can be of at least
about 1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or
60% of the enclosure side wall relative to the bottom of the
processing chamber (e.g., comprising the exposed surface of the
material bed and/or platform), wherein the percentage is along the
Y direction (wall height). That position can be of at most about
1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60% of
the enclosure side wall relative to the bottom of the processing
chamber (e.g., comprising the exposed surface of the material bed
and/or platform) wherein the percentage is along the Y direction
(wall height). That position can be between any of the
afore-mentioned values the enclosure side wall relative to the
bottom of the processing chamber (e.g., from about 1% to about 60%,
from about 1% to about 25%, from about 30% to about 45%, or from
about 45% to about 60% from the material bed). That position can be
of at least about 1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%,
50%, 55%, or 60% of the enclosure wall relative to a frontal wall
of the processing chamber (e.g., perpendicular to the bottom of the
processing chamber and to the enclosure sidewall), wherein the
percentage is along the Z direction (wall depth). That position can
be of at most about 1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%,
50%, 55%, or 60% of the enclosure wall relative to a frontal wall
of the processing chamber (e.g., perpendicular to the bottom of the
processing chamber and to the enclosure side wall), wherein the
percentage is along the Z direction (wall depth). That position can
be between any of the afore-mentioned values the enclosure side
wall relative to the frontal wall of the processing chamber (e.g.,
from about 1% to about 60%, from about 1% to about 25%, from about
30% to about 45%, or from about 45% to about 60% from the material
bed). FIG. 11A shows an example of a side enclosure wall 1140
comprising an opening 1145 that is partially obstructed by a baffle
1143. A center of the opening 1145 is disposed at about 25% of the
enclosure side wall height 1142 relative to the bottom of the
processing chamber, and at about 50% depth 1141 from a frontal
enclosure wall. FIG. 11B shows an example of a side enclosure wall
1150 comprising an unobstructed opening 1155. A center of the
opening 1155 is disposed at about 50% of the enclosure side wall
height 1152 relative to the bottom of the processing chamber, and
at about 75% depth 1151 from a frontal enclosure wall.
[0267] In some instances, the outlet portion comprises one or more
ledges. The ledge may be any ledge disclosed herein. The ledge may
be (e.g., laterally) extending from one edge of the outlet portion
(e.g., comprising the outlet opening, e.g., 872) to the opposite
edge of the outlet portion (e.g., to the internal outlet wall,
e.g., 871). The outlet portion may comprise an internal outlet wall
(e.g., 871). The internal outlet wall may be any internal wall
described herein. The aspect ratio of the internal outlet wall
relative to an outlet opening (e.g., 872) can be at least about
500:1, 250:1, 200:1, 100:1, 50:1, 25:1 or 10:1. The aspect ratio of
the internal outlet wall relative to an outlet opening (e.g., 872)
can be at most about 500:1, 250:1, 200:1, 100:1, 50:1, 25:1 or
10:1. The aspect ratio of the internal outlet wall relative to an
outlet opening can be between any of the afore-mentioned values
(e.g., from about 500:1 to about 10:1, from about 500:1 to about
100:1, from about 100:1 to about 50:1, or from about 50:1 to about
10:1). The internal outlet wall may comprise a perforated plate.
The perforated plate may be any perforated plate described herein.
In some instances, the outlet portion may comprise more than one
perforated plate. The multiple perforated plates may be stacked
(e.g., vertically, horizontally and/or at an angle). The multiple
perforated plates may be stacked parallel to each other. The
perforations may be any perforation disclosed herein. The plurality
of perforated plates may comprise 2, 3, 4, 5, 6, 7, 8, 9, or 10
perforated plates (e.g., through which the gas flows prior to entry
into the processing chamber). The perforated plate may be heated
and/or cooled. The temperature of the gas flow may be regulated
using the perforated plate. For example, the perforated plate(s)
may be operatively coupled to a heat exchanger and/or heat source.
The collective respective cross sectional area of the holes in the
perforated plates can be the (e.g., substantially) same as the
respective cross sectional collective areas of the gas entrance
openings. This may facilitate maintaining the same speed in (i) the
processing cone and in (ii) the entrance to the gas tunnel. In some
embodiments, the speed along the (e.g., entire) height of the
processing chamber and/or cone is (e.g., substantially) constant.
At times, the speed along the (e.g., entire) height of the
processing chamber and/or cone may vary. For example, the speed may
vary gradually or non-gradually (e.g., using one or more horizontal
partitions). The perforated plate can comprise space filling
polygonal openings (e.g., having hexagonal, or rectangular cross
section). The perforated plate(s) may comprise a separator,
diffuser, and/or collimator (e.g., having a cross section of a
geometric shape as described herein). The collimator may comprise
an aligning passage (e.g., channel). The polygons can be any
polygons describe herein as suitable. The space filling polygon
arrangement may be planar (e.g., in a single plane). The space
filling polygon arrangement may comprise a tessellation. The
tessellation may comprise a (e.g., symmetric) polygon. The
tessellation may comprise an equilateral polygon. The tessellation
may comprise a triangle, tetragon (e.g., quadrilateral), or
hexagon. The tetragon may comprise a concave or convex tetragon.
The tetragon may comprise a rectangle. The rectangle may comprise a
square. The perforated plate and/or cross section of the collimator
(e.g., aligning passage(s)) may comprise an oval. The oval may
comprise a circle. The cross-section of the aligning passage and/or
perforated plate hole may be a square, rectangle, triangle,
pentagon, hexagon, heptagon, octagon, nonagon, octagon, circle,
icosahedron, or any combination thereof.
[0268] In some instances, a cross section of the outlet portion is
of a geometric shape (e.g., rectangular shape, square shape,
circular shape, box shape). FIG. 12 and FIG. 13 show an example of
an outlet portion, e.g., 1240, 1340. The outlet portion may be
aerodynamically shaped (e.g., wind tunnel shape, tubular shape,
rain drop shape, rocket shape). FIG. 8 shows an example of an
aerodynamic (e.g., wind tunnel) shaped outlet portion, e.g., 870.
The aerodynamic shape may enable smooth flow of gas through the
outlet portion. The outlet portion can have a cross-section shape
that tapers toward an outlet opening (e.g., 872). The aerodynamic
shape may converge into at least one (E.g., narrow) opening before
exiting the enclosure. The aerodynamic shape may facilitate
decrease in (e.g., elimination of) gas recirculation, static
vortices and/or stagnated flow of gas, at least within the
processing cone (e.g., within the enclosure).
[0269] In some instances, the outlet portion comprises one or more
baffles (e.g., FIG. 9, 965, 970). The baffle may be placed between
the outlet opening and the processing chamber. The baffle may be
placed within an outlet portion. There may be one or more baffles
within the outlet portion. The baffle may be any baffle disclosed
herein.
[0270] In some instances, the gas flow mechanism is coupled to a
recycling mechanism. The recycling mechanism may comprise a closed
loop system. The recycling mechanism may collect the gas from the
outlet portion (e.g., 870) and/or from the outlet opening (e.g.,
872). The recycling mechanism may filter the gas. The recycling
mechanism may inject the gas into the enclosure. For example, the
recycling mechanism may inject the gas into the inlet opening
(e.g., 955), inlet portion (e.g., 940), and/or processing chamber
(e.g., 901). The injection may be direct or indirect. At least a
portion of the recycling may be performed before, after, and/or
during the 3D printing. At least a portion of the recycling may be
continuous (e.g., during at least a portion of the 3D printing).
The recycling mechanism may comprise a filtering mechanism (e.g.,
FIG. 8, 830, FIG. 14, 1460). The recycling mechanism may comprise a
device configured to remove the debris (e.g., particulate material)
from the gas. The removal may be using a filter, screen,
perforated-plate, or any combination thereof. The removal may be
using a charge such as a magnetic and/or electrical charge. For
example, the removal may comprise using an electrostatic gas
filter. The filtering mechanism may comprise a filter (e.g.,
polymer, HEPA, polyester, paper, mesh, or electrostatic gas
filter). The filter may enable a gas to flow through it. The filter
may prevent the debris from flowing through it. The filtering
mechanism may allow gas to flow through. The filtering mechanism
may separate the gas from debris (such as particulate material,
and/or soot) behind. The filtering mechanism may comprise a filter,
an outlet opening, inlet opening, canister, channel, sensor, or
valve. The filtering mechanism may comprise a pressure difference
mechanism to filter gas from the debris. The filtering mechanism
may comprise a gas removal mechanism (e.g., vacuum, or gas
channel). The suction mechanism may comprise a filter. The
recycling and/or suction mechanism may facilitate (e.g., evacuate
and/or channel) a flow of the gas from the outlet opening to the
inlet portion (e.g., through the inlet opening). At times, the gas
from the outlet opening may be conveyed via the filtering mechanism
(e.g., using positive or negative pressure, for example, using a
gas pump). The filtering mechanism may be continuously operational
during at least a portion of the 3D printing (e.g., during the
operation of the energy beam, during formation of a layer of
hardened material, during deposition of a layer of pre-transformed
material, during the printing of the 3D object). The filtering
mechanism may be controlled (e.g., before, after, and/or during at
least a portion of the 3D printing). The control may be manual
and/or automatic. The filtering mechanism may comprise a paper,
mesh, or an electrostatic filter. The filtering mechanism may
include one or more sensors (e.g. optical, pressure). The sensors
may detect incoming gas into the filtering mechanism. The sensors
may detect debris in the filter. The sensors may detect clogging of
the filter. The filtering mechanism may be done in batches and/or
continuously. The filtering mechanism may operation during at least
a portion of the 3D printing. The recycling mechanism and/or
suction mechanism may release the gas into the filtering mechanism
in batches. The release of gas may be timed. The recycling
mechanism may comprise a pump. The filtering mechanism may be
operatively coupled (e.g., connected) to the pump (e.g., FIG. 8,
835, FIG. 14, 1450). The pump may receive a filtered gas from the
filtering mechanism. The pump may be coupled to a variable
frequency drive. The variable frequency drive may allow controlling
the gas flow rate from the pump (e.g., into the enclosure). At
times, the gas flow rate may be dynamically (e.g., real time)
controlled. The control may be manual and/or automatic. The
recycling mechanism may comprise a re-conditioning system. The
re-conditioning system may recondition the gas (e.g., remove any
reactive species such as oxidizing gas, or water) The
re-conditioned gas may be recycled and used in the 3D printing.
Recycling may comprise transporting the gas to the processing
chamber. Recycling may comprise transporting the gas to the inlet
portion. Recycling may comprise transporting the gas within the
enclosure (e.g., FIG. 14, 1440, FIG. 1, 100). In some instances,
the re-conditioning mechanism may re-condition the separated
pre-transformed material that may be residual from the filtering
mechanism. The residual material may be filtered and/or collected
in a separate container (e.g., FIG. 8, 838). The re-conditioned
material may be recycled and used in the 3D printing. Recycling may
comprise transporting the material to the layer dispensing system.
The recycling may be continuous and/or in batches during at least a
portion of the 3D printing.
[0271] In some embodiments, the recycling mechanism may be coupled
to a sieve (e.g., filter). In some embodiments, gas material may be
sieved before recycling and/or 3D printing. Sieving may comprise
passing a gas borne material (e.g., liquid or particulate) through
a sieve. The sieving may comprise passing the gas borne material
using a flow of the gas, through a cyclonic separator. Sieving may
comprise classifying the gas borne material. Classifying may
comprise gas classifying. Gas classifying may comprise
air-classifying. Gas classifying may include transporting a
material (e.g., particulate material) through a channel. A first
set of gas flow carrying particulate material of various types
(e.g., cross sections, or weights) may flow horizontally from a
first horizontal side of the channel to a second horizontal side of
the channel. A second set of gas flow may flow vertically from a
first vertical side of the channel to a second vertical side. The
second vertical side of the channel may comprise material
collectors (e.g., bins). As the particulate material flows from the
first horizontal direction to the second horizontal direction, the
particulate material interacts with the vertical flow set, and gets
deflected from their horizontal flow course to a vertical flow
course. The particulate material may travel to the material
collectors, depending on their size and/or weight, such that the
lighter and smaller particles collect in the first collator, and
the heaviest and largest particles collect at the last collector.
Blowing of gas (e.g., air) may allow classification of the
particulate material according to the size and/or weight. The
material may be conditioned before use (e.g., re-use) within the
enclosure. The material may be conditioned before, or after
recycling. Examples of gas classification system can be found in
PCT patent application serial number PCT/US17/39422 filed on Jun.
27, 2017 and titled "THREE-DIMENSIONAL PRINTING AND
THREE-DIMENSIONAL PRINTERS," which is incorporated herein by
reference in its entirety.
[0272] In some embodiments, a filtering mechanism may be
operatively coupled to at least one component of the layer
dispensing mechanism, the pump (e.g., pressurizing pump), an
ancillary chamber and/or the processing chamber. The filtering
mechanism may be operatively coupled to the gas flow mechanism. For
example, the filtering mechanism may be operatively coupled (e.g.,
physically coupled) to the gas conveying channel of the gas flow
mechanism. Physically coupled may comprise flowably coupled to
allow at least flow of a gas (e.g., and gas borne material).
Operatively coupled may include fluid communication (e.g., a fluid
connection, and/or a fluid conveying channel). Fluid communication
may include a connection that allows a gas, liquid, and/or solid
(e.g., particulate material) to flow through the connection. The
filtering mechanism may be operatively coupled to an outlet portion
of the processing chamber. A gas comprising gas-borne materials
(e.g., debris, soot, reactive species, and/or pre-transformed
material) may flow through the filtering mechanism. The filtering
mechanism may be configured to facilitate separation of the
gas-borne materials from gas. The filtering mechanism may comprise
one or more filters or pumps. The one or more filters may comprise
crude filters or fine filters (e.g., HEPA filters). The one or
filters may be disposed before a pump and/or after a pump. FIG. 17
shows an example of a filtering mechanism comprising two filters
1705 and 1702 disposed before the pump 1715, and a filter 1703
disposed after the pump, wherein before and after is relative to
the direction of gas flow into the processing chamber 1720. The
filtering mechanism may be (e.g., further) facilitate flow of gas
into the processing chamber through an inlet portion. FIG. 17
schematically shows an example of a filtering mechanism. The
filtering mechanism may be operatively coupled to a processing
chamber (e.g., 1720), and/or to an ancillary chamber (e.g., 1765)
through one or more gas conveying channels (e.g., 1725, or, 1730)
and/or through one or more valves (e.g., 1735, 1740, 1745, 1750,
1770, 1772, 1774, 1776, and/or 1735). The valves may be controlled.
The control may be manual and/or automatic. The control may be
before, after, and/or during the 3D printing. The valve may
facilitate engagement and/or dis-engagement of one or more segments
of the 3D printer (e.g., one or more segments of the gas flow
mechanism). For example, the valve (e.g., 1745, 1735, 1750, 1740)
may facilitate engagement and/or dis-engagement of a filtering
mechanism with the pump and/or the processing chamber. The valve
may facilitate insertion of gas into one or more segments of the 3D
printer. For example, the valve (e.g., 1770, 1772) may facilitate
insertion of gas into the filtering mechanism. The valve may
facilitate discharge of gas from one or more segments of the 3D
printer. For example, the valve (e.g., 1774, 1776) may facilitate
discharge of a gas from the filtering mechanism. One or more
sensors, (e.g., 1755, 1760) may sense a condition and/or a physical
property (e.g., atmosphere, pressure, filtering mechanism presence
(e.g., when one or more filters is present), gas flow, amount of
gas borne material, and/or mass flow) within the one or more
segments of the 3D printer (e.g., the filtering mechanism). The
filtering mechanism may be operatively coupled to a pump (e.g.,
1715). The pump may induce gas flow in one or more segments of the
3D printer. For example, the pump may induce gas flow (e.g., gas
circulation) within the processing chamber and/or the filtering
mechanism. In some embodiments, the filtering mechanism is
configured to provide filtered gas to an optical window purging
system (e.g., 1701), examples of which are described herein.
[0273] In some embodiments, the filtering mechanism comprises one
or more canisters (e.g., 1705, 1710). The canister may comprise a
uniform or a non-uniform shape. The canister may comprise a
geometrical shape (e.g., a cylinder, sphere, rectangular, and/or
circular). The canister may comprise a 3D shape. The canister may
have an internal and/or external 3D shape. The internal shape may
be the same or different as the external 3D shape of the canister.
The canister may have a uniform or a non-uniform internal 3D shape.
The 3D shape may comprise a cuboid (e.g., cube), a tetrahedron, a
polyhedron (e.g., primary parallelohedron), at least a portion of
an ellipse (e.g., circle), a cone, a triangular prism, hexagonal
prism, cube, truncated octahedron, or gyrobifastigium, a pentagonal
pyramid, or a cylinder. The polyhedron may be a prism (e.g.,
hexagonal prism), or octahedron (e.g., truncated octahedron). A
vertical cross section (e.g., side cross section) of the 3D shape
may comprise a circle, triangle, rectangle (e.g., square, e.g.,
1820, 1825), pentagon, hexagon, octagon, or any other polygon. The
vertical cross section may be of an amorphous shape. The polygon
may comprise at least 3, 4, 5, 6, 7, 8, 9, or 10 faces. The polygon
may comprise at least 3, 4, 5, 6, 7, 8, 9, or 10 vertices. The
cross-section may comprise a convex polygon. The polygon may be a
closed polygon. The polygon may be equilateral, equiangular,
regular convex, cyclic, tangential, edge-transitive, rectilinear,
or any combination thereof. For example, the (e.g., vertical)
cross-section of the 3D shape may comprise a square, rectangle,
triangle, pentagon, hexagon, heptagon, octagon, nonagon, octagon,
circle, or icosahedron. The canister may be replaceable, removable,
exchangeable, and/or modular. The canister may be removed,
replaced, and/or exchanged before, during, and/or after 3D
printing. Removing, replacing, and/or exchanging may be done
manually and/or automatically (e.g., using at least one controller,
controlled, and/or semi-automatic). The canister may comprise a
material that facilitates entrapment of the gas borne material
and/or internal 3D printer gas (e.g., inert gas). The canister may
comprise a material that facilitates impermeability of an external
gas (e.g., air, oxidizing gas, water, and/or humidity) into the
canister. External may include an atmosphere on the exterior of the
canister. The canister may comprise a material that facilitates
minimal gas and/or liquid leaks. The material of the canister may
facilitate adherence to safety standard prevailing in the
jurisdiction, for example, by limiting the oxidizing gas and/or
humidity concentration in the canister (e.g., during and/or after
the filtering process). The limit may be based on the standard in
the jurisdiction. Example standards may include combustion and/or
ignition related standard, fire related standard (e.g., American
Society for Testing and Materials International (ASTM),
Occupational Safety and Health Administration (OSHA), Hazard
Communication Standard (HCS), Material Safety Data Sheet (MSDS),
and/or National Fire Protection Association (NFPA)). In some
embodiments, the canister may comprise a partition (e.g., a wall)
between one or more internal surfaces (e.g., solid material
surface). The partition may form a gap (e.g., a void). The gap may
be between a first internal surface and a second internal surface
of the canister. The gap may be filled with a gas. The gap may be
filled with a material different than the material of the internal
surface of the canister (e.g., a liquid, semi-solid, and/or solid
material). The gas may comprise an atmosphere. The atmosphere of
the gap may facilitate maintaining the atmosphere of the canister
to (e.g., substantially) prevent an atmospheric leak (e.g.,
permeation of gas such as an oxidizing gas, reactive agent, and/or
water). The atmosphere of the gap may be different than the
atmosphere of the canister interior. The canister may facilitate
containing gas-borne material (e.g., debris, soot, pre-transformed
material, and/or reactive species), for example, in an atmosphere
that does not react with the gas borne material. The gas-borne
material may be deposited within the canister (e.g., adhering to a
filter) as a result of filtering the gas (e.g., of flowing the gas)
from the processing chamber. The canister (e.g., a surface of the
canister) may be operatively coupled (e.g., fluidly connect) to one
or more valves. The valve may allow a flow of gas into and/or out
of the canister. The canister may comprise an entrance opening and
an exit opening. The exit opening and the entrance opening may be
in opposing sides of the canister. In some embodiments, the exit
opening and the entrance opening to the canister may be disposed on
non-opposing sides of the canister, for example, on adjacent sides
of the canister. The valve may connect the canister to a processing
chamber, a member of the layer dispenser, an ancillary chamber, a
control system, and/or a pump. The valve may be any valve disclosed
herein.
[0274] In some embodiments, the canister comprises a filter (e.g.,
a sieve, screen, a perforated plate and/or baffle). The filter may
be configured to separate the gas-borne material from the gas. The
filter may be located within an interior of the canister. The
filter may be disposed adjacent to (or connected, and/or
operatively coupled to) one or more internal surfaces (e.g., walls)
of the canister. The filter may comprise a material that
facilitates maintenance of an atmosphere within the canister. For
example, the filter may not expel the reactive agent (or precursors
thereof). For example, the filter may not expel an oxidizing gas
and/or humidity (or precursors thereof). Example filters include a
composite material, a fiber media, a paper pulp, a fiber gas,
polymer, HEPA, polyester, paper, mesh, polymeric, or electrostatic
gas filter. At times, the filter may be cleaned. Cleaning may be
done before, during, and/or after 3D printing. Cleaning may
comprise isolating the canister from the 3D printer (e.g., from the
gas flow mechanism). Cleaning may include drenching (e.g., with
water, liquid, and/or gas). The liquid may comprise a hydrophilic
and/or hydrophobic substance and/or solution. The hydrophilic
substance may comprise water. The hydrophobic substance may
comprise oil. Cleaning may require removal of the canister
comprising the filter. In some embodiments, the cleaning may be
performed without removal of the canister comprising the filter. In
some embodiments, cleaning may require removal of the filter from
the 3D printer and/or from the canister. In some embodiments, the
cleaning may be performed without removal of the filter from the
canister.
[0275] In some embodiments, the canister comprises an inlet portion
and/or an outlet portion. The inlet portion and/or outlet portion
may facilitate reconditioning (e.g., cleaning) of the filter. The
inlet portion may be located adjacent to a top surface of the
canister. Top may be in a direction away from the platform and/or
against the gravitation center. The inlet may comprise an inlet
channel (e.g., pipe, tube, and/or canal). The inlet may allow
insertion of a cleaning material. The inlet channel may extend to a
location adjacent to a surface (e.g., top) of the filter. The
outlet portion may be in an opposite side of the canister where the
inlet is located. The outlet may be located on a side of the inlet
that is different from the side opposing the inlet. In some
embodiments, the outlet does not oppose the inlet. For example, the
outlet may not directly oppose the inlet. For example, the outlet
may be located adjacent to a side surface of the canister. Adjacent
to a side surface may comprise in a direction perpendicular and/or
at an angle to the inlet. If the inlet is disposed along a vertical
line (e.g., along the gravitational vector), the outlet may be
disposed at an angle relative to the vertical line. The outlet
portion may be at an acute angle at least about 1.degree.,
2.degree., 5.degree., 10.degree., 20.degree., 30.degree.,
40.degree., 45.degree., 50.degree., 60.degree., 70.degree.,
80.degree., or 90.degree. with respect to the vertical line. The
outlet portion may be at an acute angle at most about 1.degree.,
2.degree., 5.degree., 10.degree., 20.degree., 30.degree.,
40.degree., 45.degree., 50.degree., 60.degree., 70.degree.,
80.degree., or 90.degree. with respect to the vertical line. The
outlet portion may be at an acute angle between any of the
afore-mentioned acute angle values with respect to the vertical
line, for example, from about 1.degree. to 90.degree., or from
about 1.degree. to about 30.degree., from about 30.degree. to about
60.degree., or from about 60.degree. to about 90.degree.. The
outlet portion may facilitate reconditioning (e.g., refurbishing)
of the filter, for example, by separation of the gas borne material
that adheres to the filter during the filtering operation (e.g.,
during gas circulation through the canister). The separation may be
facilitated by a cleansing material comprising a gas and/or a
liquid. The cleansing material may be a non-reactive, and/or inert
to the gas-borne material. For example, the outlet portion may
facilitate cleansing of the filter, for example, by flowing off gas
borne material that is adheres to (e.g., collected on/in) the
filter. The outlet portion may comprise an outlet channel. The
outlet channel may facilitate the flow of the gas borne material
from the filter to an area (e.g., collection area) outside the
canister.
[0276] In some embodiments, the filtering mechanism comprises one
or more valves (e.g., flow, stopper, pressure, engaging,
dis-engaging, and/or control valve). The valve may allow gas,
liquid, and/or solid to (e.g., controllably) flow through. The
solid may comprise a particulate material. The valve may allow gas,
liquid, and/or solid to (e.g., controllably) prevent from flowing
through. Examples of valves include a pressure relief, pressure
release, pressure safety, safety relief, pilot-operated relief, low
pressure safety, vacuum pressure safety, low and vacuum pressure
safety, pressure vacuum release, snap acting, pinch, metering,
flapper, needle, check, control, solenoid, flow control, butterfly,
ball, piston, plug, popping, rotary, manual, or modulating
valve.
[0277] In some embodiments, the filtering mechanism comprises one
or more sensors (e.g., presence, mass flow, pressure, temperature,
atmosphere, humidity, oxidizing gas, gas, flow, velocity, material
density, detection, clogging detection, and/or level sensor). The
sensor may sense the level of reactive gas. The reactive gas may
comprise oxygen, water, carbon dioxide, or nitrogen. The reactive
gas may react with the material used or produced during the 3D
printing. The material produced during the 3D printing may comprise
debris, or soot. The material used for the 3D printing may comprise
a particulate material (e.g., powder). The sensor may detect at
least one characteristic of the gas that flows through a filter
within the canister. The at least one gas characteristic may
comprise gas type, reactive gas level, temperature, pressure, or
flow rate. The sensor may detect a presence of a canister in the
gas flow mechanism. The sensor may detect a presence of a filter in
the filtering mechanism (e.g., in the canister). The sensor may
detect at least one gas characteristic of an atmosphere within the
canister. The at least one characteristic of the atmosphere may
comprise gas type, reactive gas level, temperature, pressure or
flow rate. The sensor may send a signal to one or more controllers
operatively coupled to the filtering mechanism. The sensors may
detect a state of at least one component of the filtering
mechanism, for example, a level of clogging of the filter, the
number of canisters present in the gas flow mechanism (as part of
the filtering mechanism), the number of canisters engaged and/or
disengaged from the gas flow mechanism, and/or the number of
canister in use. The controller may adjust one or more physical
properties (e.g., flow of gas, pressure, velocity, temperature,
reactive agent level, and/or atmosphere) of the filtering mechanism
(e.g., based on a sensor signal). The controller may adjust a flow
of gas in the gas flow mechanism (e.g., based on the amount of
clogging within the filter in the canister). For example, the
controller may adjust a flow of gas in the filtering mechanism
and/or the processing chamber (e.g., based on the amount of
clogging within the filter in the canister). The controller may
adjust the flow of gas to maintain a desired and/or requested gas
flow velocity and/or acceleration. The control may be performed
before, after, and/or during 3D printing. The control may be manual
and/or automatic.
[0278] In some embodiments, the filtering mechanism comprises one
or more indicators (e.g., visual, sound, and/or tactile). The
indicator may alert one or more human senses (e.g., sound, visual,
tactile, oral, and/or olfactory). The indicators may be a part of a
user interface, and/or touchscreen. The indicator may comprise an
optical signal. The indicators may reflect a state of the filtering
mechanism. The state of the filtering mechanism may include sensing
a signal from one or more sensors. Example states of the filtering
mechanism may include an a safe to use, ready to use, in operation,
unsafe to use, safe to change filter, and/or unsafe to change
filter. The safety indicators may correspond to the safety
standards in the jurisdiction.
[0279] In some embodiments, the 3D printing system comprises
multiple (e.g., two) filtering mechanisms. FIG. 18 schematically
shows an example of two filtering mechanisms (e.g., 1820, 1825)
operatively coupled to the ancillary chamber (e.g., 1815). The one
or more filtering mechanism may be operatively coupled to the
processing chamber (e.g., 1810) (e.g., via a gas conveying channel
1845). At times, a first filtering mechanism may be coupled to the
processing chamber. At times, a second filtering mechanism may be
coupled to the processing chamber. At times, multiple (e.g., two,
three, four, and/or five) filtering mechanisms may be coupled to
the processing chamber. The gas conveying channel may comprise a
valve (e.g., 1835). The valve may facilitate reversibly connecting
the first filtering mechanism and/or the second filtering mechanism
to the processing chamber (e.g., during, before and/or after the 3D
printing). A filtering mechanism may comprise one or more (e.g.,
two) canisters (e.g., 1820 and 1825). At times, a first canister
may be coupled to the processing chamber. At times, a second
canister may be coupled to the processing chamber. At times, the
plurality (e.g., two, three, four, and/or five) of canisters may be
coupled to the processing chamber. The multiple filtering
mechanisms may facilitate a continuous filtering of the gas that
flows within at least the processing chamber (e.g., the gas that
flows within the gas circulation mechanism comprising the
processing chamber, ancillary chamber, a component of the layer
dispenser or a pump), which continuous filtering is before, after
and/or during the 3D printing. The plurality of filtering
mechanisms may facilitate an exchange of at least one filter during
the continuous filtering of the gas that flows within at least a
portion of the gas circulation system (e.g., the processing
chamber), which continuous filtering is before, after and/or during
the 3D printing. The canisters may facilitate maintaining a
requested amount of a physical property of gas within the
processing chamber and/or ancillary chamber. The requested amount
of the physical property of the gas may be pre-determined and/or
constant. The physical property of the gas may comprise a density,
velocity, type, and/or acceleration. The physical property of the
gas may comprise an amount (e.g., contamination) of a reactive
agent in the gas. The reactive agent may comprise an oxidizing
agent. The multiple filtering mechanisms may facilitate maintaining
a constant and/or diminished amount of gas-borne material in the
processing chamber and/or ancillary chamber. In some embodiments,
the continuous filtering may comprise alternating filtering from a
first filtering mechanism and a second filtering mechanism. For
example, the continuous filtering may comprise alternating the gas
flow from flowing through a first canister (comprising a first
filter) to flowing through a second canister (comprising a second
filter). Alternating may comprise switching filtering from a first
filtering mechanism to a second filtering mechanism. Switching may
be done before, during, and/or after 3D printing. Switching may be
controlled (e.g., manually or automatically using a controller).
Alternating may comprise dis-engaging a first filtering mechanism
(e.g., comprising the canister, valve, channel, sensor, or filter).
Alternating may comprise engaging a second filtering mechanism
(e.g., comprising the canister, valve, channel, sensor, or filter).
Alternating may comprise controlling one or more valves.
Alternating may comprise detecting a status of the first filtering
mechanism and/or second filtering mechanism, for example, by
reading signals from one or more sensors. The alternating process
may comprise (i) sensing a physical property (e.g., clogging, gas
velocity, rate of gas flow, direction of gas flow, rate of mass
flow, direction of mass flow, temperature, reactive agent level,
and/or gas pressure) of flowing gas within a first filtering
mechanism, (ii) sensing a presence of a second filtering mechanism
(e.g., using a presence sensor), (iii) sensing an atmosphere and/or
a physical property (e.g., reactive agent, pressure, humidity
and/or temperature) of the second filtering mechanism, (iv)
determining that the second filtering mechanism may be present, and
optionally that the condition of the second filtering mechanism
matches an expected condition, (v) engaging the second filtering
mechanism with the processing chamber, ancillary chamber, and/or a
component of the layer dispenser, (vi) optionally, dis-engaging the
first filtering mechanism from the processing chamber, ancillary
chamber and/or a component of the layer dispenser, and (vii)
reconditioning the first filtering mechanism (e.g., cleaning and/or
replacing the first filter thereof). Operations (i)-(vii) may be
performed in any order and/or sequence, for example, sequentially.
At least two of operations (i)-(vii) may be performed in parallel.
At least two of operations (i)-(vii) may be performed sequentially.
Reconditioning the first filtering mechanism may comprise removing
the filter from the canister within the filtering mechanism.
Reconditioning the first filtering mechanism may comprise drenching
the filter within the canister. Drenching may comprise inserting a
cleaning material (e.g., liquid, gas, semi-solid, and/or any other
cleaning medium) into the filter. Drenching may be performed
before, after, or during removal of the filter from the canister.
Drenching may be performed before, after, or during the 3D
printing. Replacing the first filtering mechanism may be performed
when the second filter mechanism is in operation (e.g., during the
3D printing). Replacing may comprise replacing a canister.
Replacing may comprise replacing a filter. Engaging and/or
dis-engaging the filtering mechanism may comprise opening and/or
closing one or more valves. Engaging and/or dis-engaging the
filtering mechanism may be performed manually and/or automated
(e.g., controlled). Engaging and/or dis-engaging the plurality of
filtering mechanisms (e.g., plurality of canisters and/or filters)
may be performed sequentially and/or in parallel. Operations (iv)
and (vii) may be performed sequentially or in parallel.
[0280] FIGS. 19A-19B show examples of alternating filtering
operation between a first filtering mechanism and a second
filtering mechanism. FIG. 19A shows an example of connecting a
first filtering mechanism (e.g., 1905) to the processing chamber
(e.g., 1950) and the pump (e.g., 1955). Connecting may comprise
engaging the first filtering mechanism to the processing chamber
and/or the pump via one or more valves. Connecting the first
filtering mechanism may comprise dis-engaging the second filtering
mechanism (e.g., 1910) from the processing chamber and/or pump, via
one or more valves. Engaging may comprise opening (denoted by a
circle comprising an "X" in FIG. 19A) one or more gas flow valves
(e.g., 1925, 1915). Opening of valves may allow gas (e.g.,
unfiltered gas, and/or gas comprising gas-borne material) to flow
from the processing chamber into the first filtering mechanism.
Dis-engaging may comprise closing (denoted by a black circle in the
FIG. 19A) one or more valves (e.g., 1920, 1930). The closed valves
may isolate the second filtering mechanism from the gas flow
mechanism. At times, the first filtering mechanism and/or the
second filtering mechanism may be purged. Purging may include
inserting a gas into the first filtering mechanism (e.g., into the
filter canister) through at least one valve (e.g., 1942) and/or
into the second filtering mechanism through at least one valve
(e.g., 1944). Purging may include discharging a gas from the first
filtering mechanism through at least one valve (e.g., 1946) and/or
from the second filtering mechanism through at least one valve
(e.g., 1948). Purging the first filtering mechanism may be done
before engaging the first filtering mechanism with the gas flow
mechanism (e.g., comprising the processing chamber and/or ancillary
chamber). Purging the second filtering mechanism may be done after
dis-engaging the second filtering mechanism with the gas flow
mechanism. In some examples, purging the first filtering mechanism
and the second filtering mechanism may be done simultaneously. In
some examples, purging the first filtering mechanism and the second
filtering mechanism may be done sequentially. In some examples, the
second filtering mechanism may be purged (e.g., simultaneously)
when the first filtering mechanism in engaged and/or in operation
as part of the gas flow mechanism. When the first filtering
mechanism is engaged, the gas (e.g., filtered gas from the first
filtering mechanism) may be circulated in the processing chamber
and/or ancillary chamber (e.g., 1927). When the first filtering
mechanism may be engaged, the gas (e.g., unfiltered gas and/or gas
comprising gas-borne material from the processing chamber) may be
circulated into the first filter canister. In some examples, the
first filtering mechanism may be connected to the pump (e.g.,
1955). The pump may be disposed adjacent to the ancillary chamber,
for example, below or above the ancillary chamber. The pump may
induce a flow of gas into the processing chamber and/or the first
filtering mechanism. When the first filtering mechanism may be
engaged, one or more sensors (e.g., 1935, 1940) may control (e.g.,
detect and/or monitor) a state of the first filtering mechanism.
For example, a clogging sensor may monitor the amount of gas-borne
material collected by the first filter. At least one reactive agent
sensor (e.g., oxygen sensor and/or humidity sensor) may monitor the
amount of reactive agent within at least one component of the first
filtering mechanism. The filtering may be switched to a second
filtering mechanism on detection (e.g., on detection of a filter
full condition, and/or on reaching a pre-determined level of
reactive agent(s)) of in-operable condition of the first filtering
mechanism. The in-operable conditions may be pre-determined.
[0281] FIG. 19B shows an example of switching filtering mechanism
for filtering the gas, and may follow FIG. 19A in operating
sequence respectively. The switching may be performed (i) when at
least a portion of the first filter within the first filtering
mechanism (e.g., 1960) may be clogged or may be determined as
unsafe to use (e.g., according to a sensor, 1990), (ii) when the
second filtering mechanism (e.g., 1965) may be present and
determined as safe to use (e.g., according to a sensor, 1995),
(iii) after a predetermined amount of time, and/or (iv) after a
predetermined amount of gas flowing through the filtering
mechanism. Switching may comprise purging the second filtering
mechanism, e.g., before engaging it with at least one component of
the gas flow mechanism. Switching may comprise engaging the second
filtering mechanism with at least one component of the gas flow
mechanism (e.g., processing chamber). Engaging may comprise opening
(denoted by a circle comprising "X" in FIG. 19B) one or more valves
(e.g., 1975, 1985). Switching may comprise dis-engaging the first
filtering mechanism. Dis-engaging may comprise closing (denoted by
a black circle in FIG. 19B) one or more valves (e.g., 1970, 1980).
The engaging of first filtering mechanism and dis-engaging of
second filtering mechanism may be done simultaneously (e.g., in
parallel) or sequentially. The engaging of the second filtering
mechanism facilitates a non-interrupted filtering of gas within the
gas flow mechanism (e.g., through the processing chamber and/or the
ancillary chamber), e.g., during the 3D printing. At least one
component of the second filtering mechanism (e.g., the filter) may
be monitored. The engaging and/or dis-engaging of first filtering
mechanism and the second filtering mechanism may be performed
alternatingly to facilitate the non-interrupted filtering of gas
that flow out of (e.g., expelled from) the processing chamber
(e.g., during the 3D printing). The dis-engaged first filtering
mechanism may be removed, replaced, cleaned, refurbished, and/or
exchanged. In some examples, the dis-engaged first filtering
mechanism may be purged (e.g., using a non-reactive, and/or inert
gas). Purging the first filtering mechanism may comprise inserting
a (non-reactive) gas into the first filtering mechanism through at
least one valve (e.g., 1962). The inserted gas should not react
with the gas-borne material to exceed combustion and/or ignition
(e.g., below combustible and/or ignition standards in the
jurisdiction). The gas borne material may be collected onto the
filter in the filtering mechanism. Purging the first filtering
mechanism may comprise discharging a (non-reactive) gas from the
first filtering mechanism through at least one valve (e.g., 1972).
The non-reactive gas may be a Nobel gas. In some embodiments, the
filtering mechanisms are configured to provide filtered gas to an
optical window purging system (e.g., 1901 and 1981), examples of
which are described herein. In some embodiments, the filtering
mechanisms include fine filters (e.g., 1902, 1903, 1982 and 1983).
The fine filters may comprise HEPA filters.
[0282] In some embodiments, the filtering mechanism is operatively
coupled to a pump. The pump may facilitate flow of gas (e.g.,
filtered gas) into the processing chamber and/or through the gas
flow mechanism. The pump may facilitate recycling of gas (e.g.,
filtered gas) into the processing chamber and/or through the filter
mechanism(s). The pump may control a property of gas flow (e.g.,
rate of flow, velocity of gas, and/or pressure of gas). At times,
the pump may control a property of the gas-borne material (e.g.,
velocity, acceleration thereof in at least one component of the gas
flow mechanism). The pump may be located adjacent to the filtering
mechanism, ancillary chamber, and/or the processing chamber. The
pump may be located below, above, and/or adjacent to a side of the
ancillary chamber. The pump may be located below, above, and/or
adjacent to a side of the processing chamber. The pump may
facilitate maintaining a gas pressure within at least a portion of
a gas flow mechanism of the 3D printer. The gas flow mechanism may
comprise the processing chamber, the ancillary chamber, the build
module, the first filtering mechanism, and/or the second filtering
mechanism. The gas pressure may be controlled (e.g., to limit an
ingress of atmosphere into at least one component of the gas flow
mechanism). Controlling may comprise limiting occurrence of a
negative pressure with respect to the ambient pressure, in at least
one section of the gas flow mechanism. For example, controlling may
comprise preventing formation of a negative pressure (with respect
to the ambient pressure) in at least one section of the gas flow
mechanism. For example, controlling may comprise preventing
formation of a negative pressure (with respect to the ambient
pressure) in the gas flow mechanism. The at least one section of
the gas flow mechanism may comprise an area enclosing the pump
(e.g., behind the pump relative to a direction of the gas flow).
Controlling may comprise raising pressure (e.g., the pressure of
the recirculating gas in the gas flow mechanism) within the gas
recirculation system. The pressure may be raised such that there
may be (e.g., substantially) no negative pressure within the gas
flow mechanism, with respect to the ambient pressure. For example,
the pressure in the area enclosing the pump may be at a positive
pressure with respect to the ambient pressure, and the pressure
within the gas recirculation system may be above the pressure in
the area enclosing the pump (e.g., the area just behind the pump).
At times, the gas flow pressure within the processing chamber and
the pressure directly adjacent to the pump, may be different. The
raised pressure may be at least about 1 psi, 2 psi, 3 psi, 4 psi, 5
psi, 6 psi, 7 psi, 8 psi, 9 psi, or 10 psi above the ambient
pressure. The raised pressure may be any value between the
afore-mentioned values, for example, from about 1 psi to about 10
psi, or from about 1 psi to about 5 psi. The raised pressure may be
the pressure directly adjacent to the pump (e.g., behind the pump).
The raised pressure may be the average pressure in the gas flow
mechanism.
[0283] In some embodiments, a flow of a reactive agent (e.g., a
reactive gas, such as an oxidizing gas) can cause the gas-borne
material to react violently (e.g., react in a hazardous, dangerous,
and/or perilous manner with respect to personnel and/or equipment).
The violent reaction may comprise combustion, ignition, flaring,
fuming, burning, bursting, explosion, eruption, or flaming. The
violent reaction may be exothermic. The violent reaction may be
difficult to contain and/or control once it initiates. The violent
reaction may be thermogenic. The violent reaction may exert heat.
The violent reaction may comprise oxidation. The 3D printing system
may comprise purging. Purging may (e.g., substantially) reduce the
likelihood (e.g., prevent) that the gas-borne material violently
reacts (e.g., during the 3D printing). Purging may comprise
evacuation of a gas (e.g., comprising the reactive agent) from one
or more segments (e.g., a processing chamber, an ancillary chamber,
a build module, and/or a filtering mechanism) of the 3D printing
system. Purging may comprise evacuation of a gas (e.g., comprising
a reactive agent) from one or more segments of the gas flow
mechanism. A segment may include a compartment (e.g., processing
chamber, ancillary chamber, a build module, and/or a filtering
mechanism) and/or a channel (e.g., a gas conveying channel, and/or
a pre-transformed material conveying channel). Purging may be
performed on an individual (e.g., isolatable) segment of the 3D
printing system. The isolatable segments may be physically isolated
from the gas flow mechanism. The isolatable segments may be fluidly
isolated from the gas flow mechanism (e.g., by shutting one or more
valves). Purging may be performed on selectable segments of the 3D
printing system. Purging may be performed on all segments of the 3D
printing system. Purging may be performed individually and/or
collectively. Purging of at least two segments may be performed in
parallel. Purging of at least two segments may be performed
sequentially. Purging may comprise exchanging large quantities of
gas in a short amount of time.
[0284] In some embodiments, the reactive agent (e.g., oxygen) flows
into the gas flow mechanism at a maximal rate (e.g., during the 3D
printing). For example, the reactive agent may flow into the gas
flow mechanism at a rate of at most about 5*10.sup.-2 liters per
minute (L/min), 10.sup.-2 L/min, 5*10.sup.-3 L/min, 10.sup.--3
L/min, 5*10.sup.-4 L/min, 5*10.sup.-4 L/min, 5*10.sup.-5 L/min,
10.sup.-5 L/min, or 5*10.sup.-6 L/min. The reactive agent may flow
into the gas flow mechanism any rate between the aforementioned
rates (e.g., from about 5*10.sup.-2 L/min to about 5*10.sup.-6
L/min, or from about 10.sup.-3 L/min to about 10.sup.-5 L/min).
[0285] In some embodiments, the likelihood of the violent reaction
is a combination of the velocity of gas, gas temperature, gas
pressure, concentration of the reactive agent, concentration of the
gas-borne material, or any combination thereof. In an example, in
an elevated level of the reactive agent in the one or more segments
(at a temperature and pressure), the purging may comprise slow gas
flow (e.g., excluding use of a pump). When the reactive species
and/or gas-borne material is lowered below a threshold value (at
the temperature and pressure), purging may comprise faster gas flow
(e.g., using a pump that facilitates the faster flow of the gas).
The slow gas flow may reduce the likelihood (e.g., prevent) a
violent reaction of the reactive agent with the gas-borne material
(when the reactive agent and/or gas-borne material concentration is
height). In reduced levels of the reactive agent and/or gas-borne
material (e.g., in the temperature and pressure), faster gas flow
velocity may be (e.g., substantially) safe to use as the chance of
a violent reaction of the reactive agent with the gas-borne
material is lowered. Purging can be performed (i) without engaging
the pump, (ii) while engaging the pump, (iii) or any combination
thereof. When at most a desired low level of the reactive agent is
present in the gas flow mechanism, purging ceases, and the gas flow
mechanism engages in a maintenance mode. In some embodiments, at
most a desired low level of the reactive agent is present, and
purging is not required. In some embodiments, purging is initiated
after the maintenance mode is engaged, for example, when the level
of the reactive agent and/or gas-borne material exceeds a minimum
level (e.g., that increases the chance for the violent reaction).
In some embodiments, the gas flow mechanism may switch between the
purging mode(s) and maintenance mode, depending on the level of the
gas-borne material and/or reactive agent.
[0286] In some embodiments, purging includes (i) operating a pump
in a purging mode, termed herein as a "pump purge mode", (ii)
without operation of a pump, termed herein as a "no pump purge
mode", and/or (iii) maintaining a predetermined pressure value,
reactive agent concentration, and/or gas-borne material
concentration in the gas flow mechanism, termed herein as a
"maintenance mode." Purging may be performed in the one or more
segments of the gas flow mechanism (independently and/or
collectively) in the pump purge mode and/or the no-pump purge mode.
Purging may be performed independently in at least two segments of
the gas flow mechanism in the pump purge mode and/or the no-pump
purge mode. Purging may be performed collectively in at least two
segments of the gas flow mechanism in the pump purge mode and/or
the no-pump purge mode. The pump purge mode may include purging of
one or more selectable segments of the gas flow mechanism that are
operatively (e.g., fluidly) coupled to the pump. In some
embodiments, a designated pump is operatively coupled to a segment
of the gas flow mechanism. For example, a first designated pump may
be operatively coupled to a first segment of the gas flow
mechanism, and a second designated pump may be operatively coupled
to a second segment of the gas flow mechanism. In some examples,
the 3D printing system may comprise a (e.g., pressure) maintenance
mode. The maintenance may include maintaining a (e.g.,
pre-determined) pressure level within one or more segments of the
gas flow mechanism. The pressure maintenance mode may comprise
light purging. In some embodiments, the stream of gas evacuated in
the light purging comprises a lower rate of gas evacuation as
compares to the pump/no-pump purging modes. For example, the gas
evacuation in the light purging comprises expelling the gas from
the gas flow mechanism through a valve having a small opening
(e.g., an opening having a small cross section), as compared to the
valves used in the pump/no-pump purge modes. For example, the
(e.g., inert) gas entrance in the light purging comprises
flowing-in the (e.g., inert) gas from (e.g., from an external
source) through a valve having a small opening (e.g., an opening
having a small cross section), as compared to the valves used in
the pump/no-pump purge modes. The light purging comprises fine
tuning of the gas pressure and/or content in at least one section
of the gas flow mechanism. In some examples, the maintenance mode
excludes purging. The pressure maintenance mode may comprise
lowering (e.g., by evacuating) a concentration of a reactive agent
and/or gas-borne material from the one or more segments of the gas
flow mechanism. Atmospheric exchange (e.g., evacuation of
contaminated gas, and entrance of the requested (e.g., inert) gas)
may be continuous during the operation of the mode. The atmospheric
exchange may be performed at one or more intervals of time. The
atmospheric exchange may be performed for a predetermined amount of
time. The atmospheric exchange may be performed until a
predetermined amount of reactive agent is evacuated from the one or
more segments of the gas flow mechanism (e.g., as measured by rate
of gas evacuation). The atmospheric exchange may refer to entrance
of requested (e.g., inert) gas and evacuation of the reactive
agent, from at least a segment of the gas flow mechanism. The
purging modes may be switched before, after, and/or during 3D
printing. The purging modes may comprise (i) pump purge mode, (ii)
no-pump purge mode, and/or (iii) pressure maintenance mode.
Switching may comprise switching from a first mode to a second mode
(e.g., comprising switching the position of one or more valves
and/or the operation status of the pump). Switching may depend on a
first threshold value and/or a second threshold value of a level of
the reactive agent (e.g., oxidizing gas level). For examples,
switching from a first mode to a second mode may depend on the
first threshold value of the reactive agent in at least a section
of the gas flow mechanism. Switching from the second mode to the
first mode may depend on the second threshold value of the reactive
agent in at least a section of the gas flow mechanism. In some
examples, the first threshold value and the second threshold value
may be (e.g., substantially) the same value. In some examples, the
first threshold value and the second threshold value may be
different (e.g., forming a hysteresis). The first threshold value
may be lower than the second threshold value. The second threshold
value may be lower than the first threshold value. Switching may be
done manually and/or automatically. For example, switching between
the modes may be controlled (e.g., using a controller, and/or
processing element). Switching may comprise (i) monitoring a level
of the reactive agent, gas-borne material, gas flow velocity,
pressure, and/or temperature within one or more segments of the 3D
printing system, (ii) comparing the level with a predetermined
first threshold value and/or second threshold value of the level,
and (iii) switching from a first mode to a second mode, based on
the comparison result. For example, switching may comprise (i)
monitoring a level of the reactive agent, within one or more
segments of the 3D printing system, (ii) comparing the reactive
agent level with a predetermined first threshold value and/or
second threshold value, and (iii) switching from a first mode to a
second mode, based on the comparison result. The first threshold
value and/or second threshold value may include a range of values
from the first threshold value to the second threshold value. The
first threshold value and/or second threshold value may be at least
about 1 parts per million (i.e., ppm), 10 ppm, 20 ppm, 30 ppm, 40
ppm, 50 ppm, 60 ppm, 70 ppm, 80 ppm, 90 ppm, 100 ppm, 110 ppm, 120
ppm, 150 ppm, 200 ppm, 300 ppm, 400 ppm, 500 ppm, 600 ppm, 700 ppm,
800 ppm, 900 ppm, 1000 ppm, 1100 ppm, 1200 ppm, 1500 ppm, 2000 ppm,
2100 ppm, 2200 ppm, 2500 ppm, 2700 ppm, 3000 ppm, 3100 ppm, 3200
ppm, 3500 ppm, 3700 ppm, 4000 ppm, 4100 ppm, 4200 ppm, 4500 ppm,
5000 ppm, 6000 ppm, 6500 ppm, 7000 ppm, 8000 ppm, 9000 ppm, or,
10,000 ppm. The first threshold value and/or second threshold value
may be at most about 10 ppm, 20 ppm, 30 ppm, 40 ppm, 50 ppm, 60
ppm, 70 ppm, 80 ppm, 90 ppm, 100 ppm, 110 ppm, 120 ppm, 150 ppm,
200 ppm, 300 ppm, 400 ppm, 500 ppm, 600 ppm, 700 ppm, 800 ppm, 900
ppm, 1000 ppm, 1100 ppm, 1200 ppm, 1500 ppm, 2000 ppm, 2100 ppm,
2200 ppm, 2500 ppm, 2700 ppm, 3000 ppm, 3100 ppm, 3200 ppm, 3500
ppm, 3700 ppm, 4000 ppm, 4100 ppm, 4200 ppm, 4500 ppm, 5000 ppm,
6000 ppm, 6500 ppm, 7000 ppm, 8000 ppm, 9000 ppm, or, 10,000 ppm.
The first threshold value and/or second threshold value may be a
range between any of the afore-mentioned values, for example, from
about 1 ppm to about 10,000 ppm, from about 3000 ppm to about 5000
ppm, from about 300 ppm to about 500 ppm, from about 1 ppm to about
300 ppm, from about 1 ppm to about 500 ppm, from about 10 ppm to
about 200 ppm, from about 500 ppm to about 3000 ppm, or from about
5000 ppm to about 10000 ppm. In some examples, the first reactive
agent threshold value for switching from a no-pump purge mode to a
pump purge mode, is higher than the second reactive agent threshold
value for switching from a pump purge mode to a maintenance mode.
Higher may be by 0.25, 0.5, 1, 1.25, 1.5, 1.75, 2, 2.25, 2.5, 2.75,
3, 3.25, 3.5, 3.75, or 4 orders of magnitude.
[0287] In some embodiments, the no-pump purge mode and/or pump
purge mode comprises performing independent purging. Independent
purging may include performing purging on one or more independent
(e.g., isolatable) segments (e.g., a processing chamber, and/or a
filtering mechanism) of the 3D printing system. A segment may be
operatively coupled to a pump (e.g., in the pump purge mode). A
segment may not be coupled to a pump (e.g., in the no-pump purge
mode). The no-pump purge mode may be facilitated by the velocity of
the requested gas that is inserted (e.g., flushed) into the at
least one segment. In some embodiments, the inserted gas causes the
contaminated gas (e.g., comprising the reactive agent) to expel
from the at least one segment (e.g., through a valve, e.g., a vent
valve). One or more isolated segments of the 3D printing system may
be purged in parallel to (e.g., simultaneously with) each other.
One or more isolated segments of the 3D printing system may be
purged sequentially (e.g., first segment may be purged after a
second segment in sequence). One or more (e.g., isolated) segments
of the 3D printing system may be purged individually (e.g., neither
simultaneously, nor in a sequence), simultaneously, sequentially,
or any combination thereof. Purging a segment may comprise
controlling (e.g., reducing, lowering, and/or maintaining) a level
of a reactive agent, gas velocity, temperature, pressure, and/or
gas-borne material, such that the reactive agent level may be
within a pre-determined (e.g., configurable) threshold value,
within the segment. For example, purging a segment may comprise
controlling (e.g., reducing, lowering, and/or maintaining) a level
of a reactive agent (e.g., oxidizing gas) such that the reactive
agent level may be within a pre-determined (e.g., configurable)
threshold value, within the segment. The pre-determined threshold
value may comply with at least one safety standard in the
jurisdiction (e.g., NFPA). The pre-determined threshold value may
be within a safe value for gas circulation (e.g., at a velocity,
temperature, and/or pressure), for example, as specified in one or
more safety standards in the jurisdiction. Purging may comprise
insertion of a low reactive gas (e.g., inert gas, e.g., argon) into
at least a portion of the segment. Purging may comprise discharging
a gas (e.g., comprising a reactive gas agent, for example, an
oxidizing gas) from at least a portion of the segment. Insertion
and/or discharge of gas may comprise using one or more valves in
the segment. Purging may comprise having at least one incoming
(e.g., requested) gas through an opened inlet valve and at least
one outgoing gas through an opened outlet valve. The requested gas
may be from an external source, e.g., a gas cylinder. For example,
a gas purge inlet valve may be opened to facilitate insertion of
the requested gas into the segment. A gas purge outlet (e.g., vent)
valve may be opened to facilitate discharge of (e.g., contaminated)
gas from the segment. The gas purge inlet valve and/or gas purge
outlet (e.g., vent) valve may be operated manually and/or
automatically (e.g., controlled). The gas purge inlet valve and/or
gas purge outlet valve may be any valve described herein. The one
or more valves may be operatively (e.g., fluidly) coupled to the
segment. One or more valves may be closed to facilitate independent
and/or isolated purging of at least one segment. For example, one
or more valves of the non-selected segments (e.g., the segment that
is not selected for purging) may be closed. For example, to
facilitate purging of a first filtering mechanism, one or more
valves of a second filtering mechanism and/or processing chamber
may be closed. Purging may include controlling (e.g., monitoring,
sensing) a reactive agent level, gas temperature, gas pressure,
and/or gas velocity within the isolated segment. Purging may
include insertion and/or discharge of gas until the reactive agent
level within the segment reaches a pre-determined threshold value.
For example, independent purging may be performed until an
oxidizing gas level reaches a first threshold value (e.g., 3000
ppm). The first threshold value may be configurable before, during,
and/or after 3D printing. Independent purging may be done before,
and/or after 3D printing, for example, after a 3D printing of at
least one 3D object, between 3D printing cycles of 3D objects,
and/or between a pre-transformed material layer dispensing when
building a 3D object. Independent purging may be done during the 3D
printing, for example, the independent purging mode may be entered
into from a collective purging mode, when the gas level within one
or more segments in the collective purge mode rises above the
pre-determined threshold value for the one or more segments. In
some examples, the pump may not be in operation during the
independent purging mode (e.g., purging of independent/isolated
segments). The pump may not be in operation to (e.g.,
substantially) prevent violent reaction (e.g., ignition) of
reactive (e.g., inflammable) gas-borne material within one or more
independent/isolated segments of the 3D printing system.
[0288] In some embodiments, the no-pump purge mode and/or pump
purge mode comprises performing collective purging. Collective
purging may include purging a plurality of segments (e.g., two,
three, four, and/or five) within the 3D printing system together.
The plurality of segments may be operatively (e.g., fluidly)
coupled to the pump. A first segment may be operatively coupled to
a second segment (e.g., through the pump, valve, and/or a channel).
Collective purging may include opening one or more valves for
(fluidly) connecting one or more segments (e.g., opening one or
more valves for the processing chamber and one or more valves for
the filtering mechanism) to the pump. Opening of one or more valves
may be done (e.g., controlled) manually and/or automatically.
Collective purging may include selecting one or more segments for
purging. For example, a first filtering mechanism and a second
filtering mechanism may be selected for collective purging, and a
processing chamber may not be selected for purging. For example,
the first filtering mechanism and the processing chamber may be
selected for collective purging, and the second filtering mechanism
may not be selected for purging. In some embodiments, the pump
(e.g., a blower) is coupled to the purged sections and is in
operation when performing collective purging. In some embodiments,
the pump (e.g., a blower) is not coupled to the purged sections
and/or is not in operation when performing collective purging. The
engagement of the pump may depend on the temperature, pressure,
velocity, gas-borne material concentration, and/or reactive species
concentration, of the gas in the segments. In some embodiments, the
purging and/or maintenance may be done before the 3D printing
(e.g., to ready the 3D printer for 3D printing). The pump may
induce a gas circulation within a gas circulation loop of the gas
flow mechanism. A gas recirculation loop may comprise conveyance
(e.g., flow) of a gas (e.g., filtered and/or clean) gas into at
least a portion of the processing chamber. The gas circulation loop
may comprise conveyance of gas from the filtering and/or recycling
mechanism into at least a portion of the processing chamber. The
gas recirculation loop may comprise conveyance of gas (e.g.,
unfiltered gas including gas borne material) from the processing
chamber into the filtering and/or recycling mechanism. The
conveyance of the gas may be induced by the pump and/or by influx
of a requested (e.g., inert) gas into the gas flow mechanism.
[0289] In some embodiments, purging may comprise maintaining a
pressure level of reactive agent (e.g., an oxidizing gas), and/or
gas-borne material. Pressure may be maintained at a pre-determined
(e.g., configurable) level and/or within a pre-determined (e.g.,
configurable) range. Pressure maintenance may comprise maintaining
the same pressure in one or more selected segments (e.g., within an
error value of at most 20%, 10%, 5%, or 1%). Pressure maintenance
may comprise maintaining the same pressure in all segments that may
be operatively coupled to the pump (e.g., within an error value of
at most 20%, 10%, 5%, or 1%). Pressure maintenance may comprise
maintaining different pressure (e.g., within an error value of at
most 20%, 10%, 5%, or 1%) within different segments. Pressure
maintenance may be performed during 3D printing (e.g., when
transforming the pre-transformed material, and/or irradiating with
an energy beam). Pressure maintenance may comprise controlling
reactive agent level within one or more segments during at least a
portion of 3D printing (e.g., during operation of the energy beam).
Pressure maintenance may comprise controlling one or more valves
(e.g., a modulating valve). A modulating valve may be operatively
coupled to a segment of the 3D printing system. Pressure
maintenance may include facilitating a finer control of gas flow
into the segment (e.g., during maintenance mode). The modulating
valve may facilitate control of conveyance (e.g., insertion,
amount, and/or flow rate) of gas into at least a segment of the gas
flow mechanism. The modulation valve may have a smaller cross
section (e.g., diameter) than a purge valve (e.g., gas purge inlet
valve and/or a gas purge outlet valve). The inlet modulation valve
may facilitate slow mass flow of gas into the gas flow mechanism as
compared to a mass flow through a gas purge inlet valve. The outlet
modulation valve may facilitate slow mass flow of gas from the gas
flow mechanism as compared to a mass flow through a gas purge
outlet valve. The modulation valve (e.g., outlet and/or inlet) may
facilitate pressure maintenance within at least a portion of a
segment of the 3D printing system, that may be operatively coupled
to the pump. Pressure maintenance may include controlling the
pressure in real-time. Real time may be during at least a portion
of 3D printing (e.g., during irradiation, planarization of an
exposed surface of the material bed, dispensing pre-transformed
material, recycling, filter exchange, and/or pre-transformed
material conveyance). In some examples, during and/or after
pressure maintenance mode, gas may be circulated until occurrence
of a predetermined threshold value of a physical property (e.g.,
time, and/or temperature), or a signal (e.g., end of a 3D printing
cycle).
[0290] In some embodiments, purging may comprise maintaining a
reactive agent level (e.g., an oxidizing gas level) at a
pre-determined level and/or between a pre-determined range (e.g.,
between a first threshold value and a second threshold value, e.g.,
that form a hysteresis). The pre-determined level and/or range may
be for a plurality of segments (e.g., two, three, and/or all)
within the gas flow mechanism of the 3D printing system. The
pre-determined level and/or range may be of an individual (e.g.,
isolatable) segment of the gas flow mechanism. The pre-determined
level and/or range configured for a segment. The operation modes of
the gas flow mechanism may be switched based on the pre-determined
level and/or range. FIG. 20 shows an example of switching between
the modes based on pre-determined threshold levels. For example,
the first operation mode (e.g., 2005) may be initially performed,
when the reactive agent level is above a first threshold value. The
first mode may comprise no-pump purge mode or independent purging.
The second operation mode (e.g., 2010) may be initiated when the
reactive agent level is at or below the first threshold value. The
mode may be switched back from the second mode to the first mode
when the reactive agent level exceeds a second threshold value. The
second mode may comprise collective purging or pump purge mode. The
third operation mode (e.g., 2015) may be initiated when the
reactive agent level is at or below a third threshold value. The
third mode may comprise the maintenance mode. The third operation
mode may be entered into from the second operation mode. The third
operation mode may be switched back to a second operation mode when
the reactive agent level exceeds a fourth threshold value. The
second threshold value can be above the first threshold value. The
fourth threshold value can be above the third threshold value. The
second threshold value can be above: the third threshold value and
the fourth threshold value. The first threshold value can be above:
the third threshold value and the fourth threshold value.
[0291] In some embodiments, a segment is operatively coupled to one
or more valves. The valve may facilitate adequate (e.g., minimal)
use of gas within one or more segments of the 3D printing system.
The valve may facilitate flow of gas through the valve (e.g., FIG.
14, 1410, 1420, and/or 1462), connection of one or more segments,
and/or disconnection of one or more segments. The valve may
facilitate insertion of a (e.g., requested) gas into a segment of
the gas flow mechanism (e.g., a gas purge inlet valve, FIG. 14,
1455, 1465, and/or 1430,). The valve may facilitate discharge of a
(e.g., contaminated) gas from the segment (e.g., a gas purge vent
valve, FIG. 14, 1475, and/or 1435). The valve may facilitate
controlling a physical property (e.g., atmosphere, pressure,
temperature and/or reactive agent level) within the segment, for
example, using a modulating valve (e.g., outlet modulating valve
1445, and/or inlet modulating valve 1425). At least two valves in
the gas flow mechanism may have a different cross-section. At least
two valves in the gas flow mechanism may have the same cross
section. The valves may be manually and/or automatically
controlled. The valves may be controlled based on a signal from one
or more sensors and/or controller. Valves may be controlled (e.g.,
opened, closed and/or adjusted) before, during, and/or after the 3D
printing.
[0292] In some embodiments, one or more segments of the gas flow
mechanism may be operatively (e.g., physically and/or flowably)
coupled to the processing chamber. The coupling may be direct
and/or indirect. The coupling may be through a channel (e.g.,
through a gas conveying and/or a material conveying channel).
Examples of indirect coupling include through an atmosphere in the
segment. For example, an atmosphere of the processing chamber may
be coupled to an opening in at least one component of a layer
dispensing mechanism (e.g., recoater), the layer dispensing
mechanism may be in turn coupled to a pre-transformed material
conveyance system, e.g., that comprises a bulk reservoir. The
pre-transformed material conveyance system may be any
pre-transformed material conveyance system such as, for example,
the one described in Provisional Patent Application Ser. No.
62/471,222 filed Mar. 14, 2017, titled "OPERATION OF
THREE-DIMENSIONAL PRINTER COMPONENTS," which is entirely
incorporated herein by reference. A material removal mechanism
opening may be opened into the processing chamber atmosphere. For
example, a material dispenser exit opening may be opened to the
processing chamber atmosphere and thus fluidly connect the material
conveyance mechanism to the gas flow mechanism. The one or more
segments may include a segment that comprises a gas-borne material.
A reactive agent (e.g., reactive species such as an oxidizing gas)
within the at least one segment of the gas flow mechanism (e.g.,
filtering mechanism) may be operatively coupled (e.g., fluidly
connected and/or shared) with the pre-transformed material
conveyance system. The flow of gas-borne material within one or
more segments of the 3D printing system may violently react with
the reactive agent. To reduce the likelihood of (e.g., prevent) the
violent reaction (e.g., to ensure safety of the 3D printing system
and/or personnel), purging may be performed within the one or more
segments of the gas flow mechanism.
[0293] In some embodiments, material is ejected to the atmosphere
of the processing chamber and/or processing cone during at least a
portion of the 3D printing. At least a portion of the ejected
material may be included in the gas-borne material. At least some
of the ejected material may be returned to the material bed. For
example, at least about 1%, 5%, 10%, 20%, 30%, 50%, or 80% of the
ejected material may be returned to the material bed (e.g., after
being recycled, e.g., reconditioned and/or separated). For example,
at most about 5%, 10%, 20%, 30%, 50%, or 90% of the ejected
material may be returned to the material bed (e.g., after being
recycled, e.g., reconditioned and/or separated). The ejected
material that is returned to the material bed may be between any of
the aforementioned values (e.g., from about 1% to about 90%, from
about 5% to about 80%, or from about 5% to about 30%).
[0294] In some embodiments, (e.g., substantially) all the volume of
the processing cone (e.g., FIG. 15, 1530), is exchanged during a 3D
printing cycle at least once. The volume may comprise the
atmosphere. In some embodiments, (e.g., substantially) all the
volume of the processing chamber (e.g., FIG. 8, 826), is exchanged
during a 3D printing cycle at least once. Substantially all the
volume may be at least about 70%, 80%, 90%, 95%, 95%, or 99% of the
total volume (percentages are volume per volume). Substantially all
the volume may be any value between the afore-mentioned values
(e.g., from about 70% to about 99%, from about 80% to about 99%, or
from about 90% to about 99%). At times, the volume exchanged during
a 3D printing cycle may be exchanged at least 1 time ("*"), 2*, 3*,
4*, 5*, 6*, 7*, 8*, 9*, or 10*. The volume (e.g., atmosphere) may
be exchanged any number of times between the afore mentioned number
of times (e.g., from 1* to 10*, from 1* to 5*, or from 1* to
3*).
[0295] In some embodiments, the gas flows at a speed in the
processing cone and/or processing chamber. The gas flow may be from
one end of the processing chamber to its opposing end. The gas flow
may be from one end of the processing cone to its opposing end. The
gas may flow laterally. At least a portion of the gas flow may be
horizontal. At least a portion of the gas flow may be laminar. The
(e.g., average or mean) speed of the gas flow may be at least about
10 millimeters per second (mm/sec), 20 mm/sec, 50 mm/sec, 80
mm/sec, 100 mm/sec, 200 mm/sec, 400 mm/sec, or 500 mm/sec. The
(e.g., average or mean) speed of the gas flow may be at most about
20 mm/sec, 50 mm/sec, 80 mm/sec, 100 mm/sec, 200 mm/sec, 4000
mm/sec, or 600 mm/sec. The (e.g., average or mean) speed of the gas
flow may be at any value between the afore-mentioned values (e.g.,
from about 10 mm/sec to about 600 mm/sec, from about 10 mm/sec to
about 300 mm/sec, or from about 50 mm/sec to about 200 mm/sec).
[0296] In some instances, the atmosphere (e.g., comprising a gas)
is exchanged (e.g., during the 3D printing or a portion thereof).
Exchanged may comprise changing the position of one or more
atmospheric components (e.g., gas and/or debris). In some examples,
the time it takes for an atmospheric component to leave the
processing cone and/or chamber is at most about 1 second, 2 sec, 5
sec, 8 sec, 10 sec, 15 sec, 20 sec, 30 sec, 50 sec, 1 min, 5 min,
10 min, or 30 min. In some examples, the time it takes for an
atmospheric component to leave the processing cone and/or chamber
is of any time values between the afore-mentioned values (e.g.,
from about 1 sec to about 30 min, from about 1 sec to about 30 sec,
from about 1 sec to about 15 sec, or from about 5 sec to about 1
min). In some embodiments, the gaseous atmosphere is flowing during
at least a portion of the 3D printing. The gaseous atmosphere may
flow at a rate of at least about 10 cubic feet per minute (CFM), 20
CFM, 30 CFM, 50 CFM, 80 CFM, 100 CFM, 300 CFM, 500 CFM, 800 CFM,
1000 CFM, or 3000 CFM. The gaseous atmosphere may flow at a rate
between any of the afore-mentioned rates (e.g., from about 10 CFM
to about 3000 CFM, from about 10 CFM to about 1000 CFM, or from
about 100 CFM to about 500 CFM). The gaseous atmosphere may be
translated by a pump (e.g., a blower).
[0297] In some examples, the processing cone and/or processing
chamber is devoid of standing vortices, and/or turbulence that are
larger than a threshold value. For example, the processing cone
and/or processing chamber may be devoid of standing vortices,
and/or turbulence that have a FLS of at least about 0.25 millimeter
(mm), 0.5 mm, 1 mm, 2 mm, 5 mm, 10 mm, 15 mm, 20 mm, or 50 mm. The
processing cone may be devoid of standing vortices, and/or
turbulence that have a FLS greater than any value between the
afore-mentioned values (e.g., from about 0.25 mm to about 50 mm,
from about 0.5 mm to about 20 mm, or from about 1 mm to about 20
mm). In some embodiments, the processing chamber and/or processing
cone may be (e.g., substantially) devoid of standing vortices
and/or turbulence. The standing vortex may be horizontal, angular,
and/or angled.
[0298] In some embodiments, a non-gaseous material is disposed in
the atmosphere. The material may be debris (e.g., soot), or
pre-transformed material (e.g., powder). The material may be
dispersed in the atmosphere of the processing chamber and/or cone.
The debris may be ejected to the atmosphere of the processing
chamber and/or cone during at least a portion of the 3D printing.
In some embodiments, most of the material that is ejected during
the 3D printing is evacuated by the gas flow. Most of the evacuated
material may be at least about 70%, 80%, 90%, 95%, 98%, or 99% of
the total material (percentages are volume per volume).
Substantially all the material may be any value between the
afore-mentioned values (e.g., from about 70% to about 99%, from
about 80% to about 99%, or from about 90% to about 99%).
[0299] In some embodiments, during at least a portion of the 3D
printing, pre-transformed material is transformed (e.g., using an
energy beam). The transformed material may transfer to the
atmosphere of the processing cone and/or processing chamber (e.g.,
as debris and/or plasma). At times, at least a portion of the
material that transfers to the atmosphere may have a (e.g., average
or mean) FLS of at most about 20 micrometers (.mu.m), 15 .mu.m, 10
.mu.m, 8 .mu.m, 5 .mu.m, 4 .mu.m, 3 .mu.m, 2 .mu.m, 1 .mu.m, or 0.5
.mu.m. At least a portion of the material that transfers to the
atmosphere may have a (e.g., average or mean) FLS of any value
between the afore-mentioned values (e.g., from about 15 .mu.m to
about 15 .mu.m, from about 15 .mu.m to about 15 .mu.m, from about
15 .mu.m to about 15 .mu.m, from about 15 .mu.m to about 15 .mu.m).
The portion of the material that transfers to the atmosphere having
the above-mentioned (e.g., average or mean) FLS, may be at least
about 70%, 80%, 90%, or 95% of the total material that transfers to
the atmosphere (e.g., debris ejected by the vaporization of the
transformed material, e.g., using the energy beam). The portion of
the material that transfers to the atmosphere may be carried by the
gas flow.
[0300] In some embodiments, the atmosphere of the processing cone
and/or chamber comprises debris and/or particulate material. The
debris and/or particulate material may be at most 100 ppm, 50 ppm,
10 ppm, 5 ppm, 1 ppm, 500 ppb, 250 ppb, 150 ppb, 100 ppb, or 50 ppb
of the volume of the processing cone and/or chamber (calculated
weight per weight). The debris and/or particulate material may be a
portion of the volume of the processing cone and/or chamber
(calculated weight per weight) between any of the afore-mentioned
values (e.g., from about 100 ppm to about 50 ppb, from about 10 ppm
to about 50 ppb, from about 5 ppm to about 50 ppb, or from 1 ppm to
about 50 ppb).
[0301] In some embodiments, particulate material and/or debris is
ejected into the atmosphere of the processing chamber and/or
processing cone during at least a portion of the 3D printing. In
some embodiments, at least a portion of the ejected material
(comprising debris and/or particulate material) remains in the
processing cone and/or processing chamber for at least about 0.1
second (sec), 0.2 sec, 0.5 sec, 1 sec, 5 sec, 10 sec, 30 sec, 50
sec, or 80 sec. In some embodiments, the at least a portion of the
ejected material remains in the processing cone and/or processing
chamber for any time period between the above-mentioned time
periods (e.g., from about 0.1 sec to about 80 sec, from about 0.5
sec to about 10 sec, from about 0.1 sec to about 5 sec, or from
about 0.1 sec to about 10 sec). The at least a portion of the
ejected material that remains in the processing chamber and/or cone
(e.g., for the above-mentioned time (periods)) may be at most about
0.001%, 0.005%, 0.01%, 0.05%, 0.1%, 0.5%, or 1% of the total
ejected material (calculated either volume per volume or weight per
weight).
[0302] In some embodiments, the gas flow mechanism comprises one or
more sensors (e.g., FIG. 14, 1470, 1480, 1485, 1490, 1495, 1415 and
1416). The sensor may (e.g., continuously) operate during at least
a portion of the 3D printing process. The sensor may be controlled
(e.g., manually and/or automatically). For example, the sensor may
be activated and/or de-activated by a controller. The sensor may be
placed between the enclosure and the recycling system. The sensor
may be placed within the enclosure. The sensor may be placed
between the inlet portion and the processing chamber. The sensor
may be placed between the outlet portion and the processing
chamber. The sensor may comprise pressure sensors, position
sensors, velocity sensors, optical sensors, mass flow sensors, gas
flow sensors, motion sensors, thermal sensors, pressure
transducers, or any other sensor mentioned herein.
[0303] In some embodiments, the controller is operatively coupled
to any system, mechanism, or apparatus disclosed herein (or any of
their components). The term "operatively coupled" or "operatively
connected" refers to a first mechanism that is coupled (or
connected) to a second mechanism to allow the intended operation of
the second and/or first mechanism.
[0304] In some embodiments, the gas flow mechanism includes a
controller (e.g., a variable frequency driver) to control the gas
flow rate. The gas flow mechanism may sense the rate of gas flow
and/or the rate of mass flow. Gas flow sensors may comprise sensing
the volumetric flow of gas. Mass flow sensors may comprise sensing
the mass flow of gas. Based on the sensed rate, the controller may
direct the inlet portion and/or outlet portion to alter the amount
of gas flow. The alteration of the gas flow may comprise (i)
closing an opening at least in part, (ii) reshaping the opening,
(iii) changing a position of a ledge, or (iv) changing a position
of a baffle. The magnitude and/or velocity of gas may be
controlled. Based on the sensed rate of velocity and/or magnitude
of the sensed gas, the velocity and/or magnitude of gas that exits
the recycling mechanism may be altered. Altered may comprise
increasing the gas velocity. Altered may comprise decreasing the
gas velocity. Altered may comprise statically setting the velocity
of the gas. Altered may comprise dynamically changing the velocity
of the gas (e.g., based on a sensed gas value). The dynamic change
may comprise a closed loop control. The dynamic change may comprise
a feedback loop control. The dynamic change may comprise comparison
to a target value. Altered may comprise statically setting the
magnitude of gas. Altered may comprise dynamically changing the
magnitude of gas.
[0305] In some embodiments, the gas flow mechanism comprises a
sensor (e.g., optical sensor) that senses a composition of gas. The
sensor may be operatively coupled to a gas filtering mechanism. The
sensor may sense impurities (e.g., oxygen, water) within the gas.
The sensor may sense reactive species (e.g., oxidizing gas, water)
within the gas. The gas may be reconditioned based on the sensed
impurities.
[0306] In some embodiments, the gas flow mechanism comprises at
least one sensor that senses the amount of debris in the enclosure.
For example, the sensor may be an optical sensor. For example, the
sensor may be a plasma. The sensor may be a spectroscopic sensor.
The sensor may be operatively coupled to the pump and/or to the
valve. A controller may control the velocity of at least one gas
stream (e.g., within the multiplicity of incoming gas streams to
the processing chamber). The control may take into account a signal
from the sensor. For example, when the enclosure contains a large
amount of debris, the controller may direct a stronger flow of the
gas at least into the processing cone (e.g., into the enclosure).
For example, when the enclosure contains a small amount of debris,
the controller may direct a softer flow of the gas at least into
the processing cone (e.g., into the enclosure). The at least one
sensor may sense a debris in a portion of the enclosure (e.g., in
the processing cone). The at least one sensor may comprise a
plurality of sensors. A controller may individually control the
velocity of at least two of a plurality of gas streams (e.g.,
within the multiplicity of incoming gas streams to the chamber). A
controller may collectively control the velocity of at least two of
a plurality of gas streams (e.g., within the multiplicity of
incoming gas streams to the chamber). At times, at least two gas
streams are controlled by separate controllers (e.g., that makeup a
control system). At times, at least two gas streams are controlled
by the same controller. The control may take into account a signal
from the sensor which provides information on the concentration,
type, and/or location of the debris at least in the processing cone
(e.g., in the processing chamber). For example, the processing cone
may contain a large amount of debris in a first enclosure
atmosphere location and a small amount of debris in a second
enclosure atmosphere location, the controller may direct a stronger
flow of the gas to the first location and a softer stream of gas to
the second location. The first and second atmosphere locations may
differ in their horizontal and/or vertical position.
[0307] In some embodiments, the controller adjusts the relative
flow of the individual gas streams based on a debris in a
particular position in at least the atmosphere of the processing
chamber (e.g., in the enclosure). For example, when the enclosure
contains debris that slows down the flow of a gas stream, the
controller may direct an increase of the flow of that gas stream
(e.g., to that position), and/or slowing down the gas flow in
adjacent gas streams (e.g., to direct the debris towards that
adjacent gas streams). For example, when the enclosure contains
debris that absorbs and/or deflects the energy beam that is
directed towards the material bed (e.g., FIG. 8, 801), the
controller may direct an increase of the flow of that gas stream
(e.g., to that position), and/or slow down the gas flow in adjacent
gas streams (e.g., to direct the debris towards that adjacent gas
streams).
[0308] In some embodiments, the gas flow mechanism comprises one or
more valves and/or gas apertures (e.g., gas opening-ports). The
valve and/or a gas aperture may be disposed adjacent to the
recycling system. The valve and/or a gas aperture may be disposed
adjacent to the pump. The valve and/or a gas aperture may be
disposed between the processing chamber and the recycling system.
The valve and/or a gas aperture may be disposed adjacent to the
inlet portion. The valve and/or a gas aperture may be disposed
adjacent to the outlet portion. FIG. 14 shows an example of valves
(e.g., 1410, 1420). The gas may travel (e.g., enter and/or exit)
through the valve. The valve may control the amount, and/or
direction of gas flow through it. The valve may control if a gas
does or does not flow through it. For example, the gas may enter or
exit the build module, processing chamber, and/or enclosure through
the valve. The valves may control (e.g., regulate) the flow of gas
to and/or from a compartment. The compartment may comprise the
enclosure, pump or the recycling mechanism. The valves may be a
pneumatic control valves. The valves may isolate the filter from
the enclosure and/or pump. Examples of valves comprise butterfly
valve, relief valve, ball valve, needle valve, solenoid valve, leak
valve, pressure gauge, or a gas inlet. The valve may comprise any
valve disclosed herein. The valve may be controlled manually and/or
electronically (e.g., by a controller). The control of the valve
may be during at least a portion of the 3D printing.
[0309] In some cases, a 3D printing system includes features that
cooperate with or compensate for certain flow dynamics of gas
within an enclosure. At times, a power density of an energy beam
that reaches a target surface can be altered (e.g., reduced) due to
being absorbed by and/or reflected from gas-borne debris (e.g.,
soot) that is generated during a 3D printing. The target surface
may comprise an exposed surface of a material bed, or an exposed
surface of a 3D object. The gas-borne debris may deposit onto at
least one surface within the enclosure (such as surfaces of an
optical window) which deposited debris can reduce a power density
of the energy beam that reaches the target surface. Providing a gas
flow across the target surface (an exposed (e.g., top) surface of a
material bed) may be used to alter (e.g., lessen) a concentration
of the debris within at least a portion of the processing chamber
during, before, and/or after a 3D printing (e.g., in a controlled
manner).
[0310] In some embodiments, the processing chamber and build module
are reversibly separable components (e.g., can reversibly and/or
controllably engage and disengage) while, in other embodiments, the
processing chamber and build module are portions of an inseparable
single unit. The processing chamber and the build module can
combine to form an enclosure for 3D printing. The 3D printer can
comprise a build module that includes a platform. In some
embodiments, the platform is configured to support and move
material bed, which is comprised of pre-transformed material (e.g.,
metal powder). The energy source can be configured to generate an
energy beam, which can be used to transform a pre-transformed
material (e.g., of material bed, or a material bed that flows
towards the platform) to a transformed material. In some
embodiments, an optical mechanism is used to control the energy
beam (e.g., control the trajectory of energy beam 2108 in
processing chamber 2102). FIG. 21 shows an example of a 3D printer
2100 which includes features for controlling gas flow. The 3D
printer 2100 includes a processing chamber 2102, build module 2104
and a material bed 2113 disposed above a platform 2112, and a 3D
object 2121 disposed in the material bed. The 3D printer 2100 is
operatively coupled to an energy source 2106 that generates an
energy beam 2108, which energy beam is directed by an optical
mechanism 2111 towards the material bed and/or a target surface
(e.g., of the 3D of the 3D object 2121), which energy beam travels
through an optical window 2103 and an atmosphere of the main
internal space 2127 (also referred to herein as the "main internal
portion of the processing chamber") of the processing chamber
2102.
[0311] In some embodiments, the 3D printer comprises gas flow in
the processing chamber. The gas flow can be before, after, and/or
during the 3D printing. The gas flow can be controlled manually
and/or automatically. The automatic control may comprise using one
or more controllers, e.g., as described herein.
[0312] In some embodiments, the processing chamber is operatively
coupled (e.g., physically connected) or may comprise a gas inlet
portion (which may also be referred to herein as "inlet portion",
"entrance portion" or "first portion"). In some embodiments, the
gas inlet portion is operatively coupled to (e.g., physically
connected) or may comprise (e.g., is an integral part of) the
processing chamber. The gas inlet portion may be configured to
facilitate gas flow therethrough. The gas inlet portion may
comprise a gas inlet port (which may also be referred to herein as
"inlet port", "entrance port", "first inlet port", "first entrance
port") and/or a gas outlet port (which may also be referred to
herein as "outlet port", "exit port", "first outlet port" or "first
exit port"). In some examples, the processing chamber may be
operatively coupled to the gas inlet portion (e.g., mainly or only)
through the gas outlet port of the gas inlet portion. The gas inlet
portion may be configured to enclose the gas. The gas inlet portion
may comprise a 3D (e.g., geometric) shape. The gas inlet portion
may enclose an internal space. The gas inlet portion may be
configured to reduce an ambient atmosphere from entering the gas
inlet portion (e.g., at least during the 3D printing). The gas
inlet portion may comprise a positive pressure (e.g., above an
ambient pressure), e.g., before, after and/or during the 3D
printing. The pressure within the gas inlet portion may be
controlled (e.g., automatically and/or manually) before, after,
and/or during the 3D printing. The gas inlet portion may comprise
one or more channels and/or baffles. The channels may be formed
using the one or more baffles. The one or more baffles may contact
(e.g., border) one or more walls of the gas inlet portion. The
inlet portion (e.g., channels within) may facilitate a gas flow
therethrough. For example, the channels and/or baffles may
facilitate altering a behavior of (i) the gas that flows
therethrough and/or (i) the gas that is expelled from the gas inlet
portion. For example, the (e.g., 3D) shape of the gas inlet portion
may facilitate altering the behavior of the (i) gas that flows
therethrough and/or (i) the gas that is expelled from the gas inlet
portion. For example, the (e.g., 3D) shape of the gas inlet port
and/or gas outlet port of the gas inlet portion may facilitate
altering the behavior of the (i) the gas that flows therethrough
and/or (i) the gas that is expelled from the gas inlet portion. The
gas may enter the gas inlet portion through its gas inlet port, and
exit the gas inlet portion through its gas outlet port. The gas may
enter the processing chamber (e.g., or the main portion of the
processing chamber) and flow over (and/or on) a target surface
(e.g., an exposed surface of the material bed and/or the 3D
object). In some embodiments, the gas inlet portion (e.g., its 3D
shape, channel(s), baffle(s), inlet port(s), and/or outlet port(s))
is configured to provide a uniform flow of gas that is
substantially parallel (e.g., parallel) to the target surface. In
some embodiments, the gas inlet portion (and/or any component
thereof) is configured to direct the flow of gas in a first
direction (e.g., x direction), and/or alter (e.g., reduce) a flow
of gas in a second direction (e.g., y direction). The first
direction may be different than the second direction. The first
direction may be (e.g., substantially) orthogonal to the first
direction (e.g., x direction). Altering the gas flow may comprise
altering the velocity, direction, laminarity, turbulence, cross
sectional shape, and/or cross-sectional area of the gas flow. The
cross section may be in a direction orthogonal to the direction of
the gas flow. In some embodiments, the gas inlet portion is
configured to provide a (e.g., substantially) uniform flow of gas
that is directed toward a target surface. In some embodiments, the
gas inlet portion is configured to provide a (e.g., substantially)
uniform flow of gas that is directed away from a target surface. In
some embodiments, the gas inlet portion is configured to provide a
(e.g., substantially) uniform flow of gas that is directed
tangential or parallel to the target surface. In some embodiments,
the gas inlet portion is configured to provide a flow of gas above
a target surface.
[0313] The gas may exit the processing chamber through a gas outlet
portion (also referred to herein as the "outlet portion" or "second
portion"). In some embodiments, the gas outlet portion is
operatively coupled (e.g., physically connected) or may comprise
(e.g., is an integral of) the processing chamber. The gas outlet
portion may be configured to facilitate gas flow therethrough. The
gas outlet portion may comprise a gas inlet port (also referred to
herein as "inlet port" or "second inlet port") and/or a gas outlet
port (also referred to herein as "outlet port" or "second outlet
port"). The gas may enter the gas outlet portion through its gas
inlet port, and exit the gas outlet portion through its gas outlet
port. In some examples, the processing chamber may be operatively
coupled to the gas outlet portion (e.g., mainly or only) through
the gas inlet port of the gas outlet portion. The gas outlet
portion may be configured to enclose the gas. The gas outlet
portion may comprise a 3D (e.g., geometric) shape. The gas outlet
portion may enclose an internal space. The gas outlet portion may
be configured to reduce an ambient atmosphere from entering the gas
inlet portion (e.g., at least during the printing). The gas outlet
portion may comprise a positive pressure (e.g., above an ambient
pressure), e.g., before, after and/or during the 3D printing. The
pressure within the gas outlet portion may be controlled (e.g.,
automatically and/or manually) before, after, and/or during the 3D
printing. The gas outlet portion may comprise one or more channels
and/or baffles. In some embodiments, the gas outlet portion is
clear of channels and/or baffles. The gas outlet portion may
facilitate a gas flow therethrough (e.g., channel gas flow within).
For example, the gas outlet portion can have channels, baffles,
and/or a 3D shape that can facilitate altering and/or preserving a
behavior of the gas that flows therethrough. The gas outlet portion
can include features that reduces an occurrence of at least some
the gas that enters the gas outlet portion (e.g., exiting the
processing chamber or the main portion of the processing chamber)
from returning to at least an area occupied by the processing cone,
which may otherwise generate standing vortices at least in the
region (e.g., volume) occupied by the processing cone or generating
turbulence at least in the region occupied by the processing cone
(e.g., in the main portion of the processing chamber), or any
combination thereof. In some embodiments, features of the gas
outlet portion (e.g., its 3D shape, channel(s), baffle(s), its
inlet port(s), and/or its outlet port(s)) are configured to provide
a flow of gas that is (e.g., substantially) free of turbulence,
standing vortices, and/or back flow. In some embodiments, the
features of the gas outlet portion (and/or an combination thereof)
are configured to direct the flow of gas towards the outlet port of
the gas outlet portion. In embodiments, the gas outlet portion is
configured to alter the gas flow as it flows therethrough. Altering
the gas flow may comprise altering the velocity, direction,
laminarity, turbulence, cross sectional shape, and/or
cross-sectional area of the gas flow. The cross section of the gas
outlet portion may vary in order to efficiently direct gas out of
its outlet port. For example, the gas outlet port may direct some
of the flow of gas in a direction orthogonal to a main direction of
the gas flow. In some embodiments, the gas outlet portion is
configured to provide a (e.g., substantially) non-turbulent flow of
gas that is directed towards its outlet port and/or away from the
processing chamber (e.g., the processing cone). The gas outlet
portion may be separated from a main internal portion of the
processing chamber by a wall (e.g., comprising an opening). The gas
outlet portion can have a tapered shape (aerodynamic shape). An
internal surface of the processing chamber can include a curvature
(e.g., facilitating an aerodynamic shape). As the gas exits the
outlet port of the gas outlet portion, the aerodynamic shape can be
configured (e.g., designed) to (i) concentrate the gas flow, (ii)
lessen back flow, (iii) lessen generation of turbulence, (iv)
lessen generation of standing vortices, or (v) any combination
thereof. Reducing the turbulence, standing vortices, and/or back
flow is at least within the area confined by the processing
cone.
[0314] FIG. 21 shows an example of a gas flow route, which gas
enters through inlet port 2116 of gas inlet portion 2114 (e.g.,
along the direction of the arrow above numeral 2116), exits the gas
inlet portion 2114 through outlet port 2124 into the main internal
portion 2127 of the processing chamber 2102, flows over (and/or on)
surface 2120 of the material bed 2113 and/or 3D object 2121 in a
general direction 2119, enters the gas outlet portion 2117 through
an inlet port 2130, and exits the gas outlet portion through outlet
port 2118. FIG. 21 shows an example of an internal surface 2128 of
the processing chamber. The gas inlet portion (e.g., 2114) can be
separated from the main internal portion (e.g., 2127) of the
processing chamber by a wall (e.g., 2132), also referred to as a
first wall. The gas outlet portion (e.g., 2117) can be separated
from the main internal portion (e.g., 2127) of the processing
chamber by a wall (e.g., 2131), also referred to as a second wall.
In some cases, the gas flows through one or more openings (e.g.,
slit(s)) (e.g., 2140) within the wall. In some embodiments, the
size of one or more openings is adjustable (e.g., able to be made
larger and/or smaller). The adjusting can change a flow of the gas
entering the outlet portion. The adjusting can be accomplished
using, for example, one or more adjustable valves. In some cases,
the gas outlet portion and main internal portion are not separated
by a wall. In the example shown in FIG. 21, the inlet portion
comprises baffles 2115 that form a (e.g., winding) channel. In the
example shown in FIG. 21, the outlet portion is devoid of baffles.
The general direction of gas flow shown in the example of FIG. 21,
is illustrated by arrows e.g., next to numerals 2116, 2119, and
2126.
[0315] The gas may flow at least in the processing cone (e.g., in
the processing chamber) in a prescribed velocity (e.g., range of
velocities), as described herein. The gas may flow at least in the
path of the energy beam through the processing chamber. The
velocity may be high enough to remove gas-borne debris from the
processing chamber atmosphere (e.g., atmosphere of 2127) and low
enough such that the pre-transformed material in the material bed
will (e.g., substantially) remain in the material bed and/or not
become (e.g., substantially) gas-borne, at least (i) in the area
occupied by the processing cone and/or (ii) above target surface of
material bed. In some embodiments, the gas flow has a velocity of
at least about 0.1 meters per second (m/s), 0.5 m/s, 1 m/s, 5 m/s,
10 m/s, 20 m/s, 50 m/s, 100 m/s, 200 m/s, 400 m/s, 500 m/s, 750
m/s, or 1000 m/s. In some embodiments, the velocity of gas flow
above the target surface ranges between any of the above-referenced
velocities, as suitable (e.g., from about 0.1 m/s to about 5 m/s,
from about 5 m/s to about 20 m/s, from about 5 m/s to about 100
m/s, from about 100 m/s to about 1000 m/s, from about 0.01 m/s to
about 1000 m/s, etc.).
[0316] In some embodiments, one or more characteristics of
gas-borne debris are measured (e.g., in situ and/or in real time,
e.g., during the 3D printing). For example, the debris may flow
with a velocity at least in the processing cone (e.g., in the
processing chamber). The debris velocity can be measured using any
suitable device(s). For example, a device that articulates a
triangulation measurement method. The device may comprise one or
more sensors. The one or more sensors may comprise an optical
sensor (e.g., a digital camera device, a single pixel detector, a
detector that detects a range of wavelengths, a single wavelength
detector, or a spectrometer). The one or more sensors may be
configured to measure the one or more energy beams (or their
respective reflections). For example, a plurality of energy beams
(e.g., two or more lasers) can be directed in a region within the
processing cone (e.g., within the processing chamber). The one or
more sensors may be operatively coupled to the plurality of energy
beams (e.g., respectively). In some examples, one sensor is coupled
to at least two energy beams. In some examples, at least two of the
energy beams are each coupled to its own (different) sensor. In
some embodiments, at least one, two, or three of the plurality of
energy beams are stationary during the measurement. The radiation
of the energy beam may comprise continuous or discontinuous (e.g.,
pulsing) radiation. In some embodiments, at least one, two, or
three of the plurality of energy beams are moving during the
measurement. The movement of the at least one of the plurality of
energy beams may comprise linear or curved movement. The movement
of the at least one of the plurality of energy beams may comprise
continuous or discontinuous (e.g., pulsing) movement. The movement
may be along a (e.g., predetermined) path. The movement velocity
may comprise a constant or varying velocity. In some examples, a
first beam and a second beam may travel in the processing chamber
(e.g., atmosphere thereof) towards a target surface. For example,
during the measurement, the first energy beam can be stationary at
a position, while the second energy beam can be move along a
trajectory (e.g., in a circular motion) in the vicinity (e.g.,
around) that position. The first and/or second energy may interact
and/or react with a debris during the measurement. The interaction
may comprise reflectance, absorbance, or a photochemical reaction.
The interaction may induce a change in that energy beam (e.g., or
to its reflection). For example, a change in intensity, direction,
and/or wavelength of the energy beam. The one or more sensor may
sense (e.g., a difference in) a signal from the first energy beam
(or its reflection) and a signal from the second energy beam (or
its reflection). The sensed signals may be compared to each other
(e.g., using a processor) and produce a result. For example, the
first energy beam (or its reflection) may be compared with the
second energy beam (or its reflection) and produce a result. The
processor and the one or more sensors may be used to determine an
amount (e.g., via density or concentration measurement(s)) and/or a
velocity of debris particles within, for example, a processing cone
of the energy beam. A detection system (e.g., comprising the one or
more sensors) can detect at least one difference in the optical
property(ies) of each of the plurality of energy beams, to
determine a velocity and/or material properties of debris in that
position and/or that vicinity. The optical properties may be
corresponding to a reflectance, or absorbance of an energy beam
that interacts with the (e.g., moving) debris. The optical
properties may comprise intensity, wavelength, etc. Examples of
various detectors and components thereof are disclosed, for
example, in PCT patent application published as WO/2016/094827,
which is incorporated herein by reference in its entirety.
[0317] In some embodiments, the gas inlet portion comprises one or
more gas-flow structures that are configured to form a (e.g.,
uniform) gas flow above the target surface (e.g., the exposed
surface of the material bed). The flowing gas may have a volume.
The flow of gas through the 3D printer may divided to one or more
flow sections. In a section of its flow in the 3D printer, the
volume of the flowing gas may be (i) constant, (ii) expand, or
(iii) contract, as a function of the distance in a first direction
(e.g., X direction in FIG. 21). In a section of its flow in the 3D
printer, the volume of the flowing gas may be (i) constant, (ii)
expand, or (iii) contract, as a function of the distance in a
second direction (e.g., Y direction in FIG. 21). In a section of
its flow in the 3D printer, the volume of the flowing gas may be
(i) constant, (ii) expand, or (iii) contract, as a function of the
distance in a third direction (e.g., Z direction in FIG. 21). The
first direction may be from the entry of the gas to the 3D printer
to the exit of the gas from the 3D printer. The second and/or third
direction may be perpendicular to the first direction. The second
direction may be perpendicular to the third direction. The volume
defined by the gas flow may comprise a cross section (e.g., in a
direction perpendicular to the direction of gas flow from the gas
inlet port to the gas outlet port, and/or in the first direction),
which cross section has a FLS. In some embodiments, the gas-flow
structure (e.g., gas channel structure) may define a path that is
configured to facilitate expansion of a gas flow from a first FLS
of the gas flow to a larger second FLS of the gas flow in the third
direction (e.g., Z axis in FIG. 21) while the gas flow advances
along the first direction (e.g., X axis). The expansion may be to a
FLS which equals at least the width of the target surface (e.g.,
width of the platform and/or exposed surface of the powder bed). In
some embodiments, the gas-flow structure may define a path that is
configured to facilitate expansion of a gas flow from a first FLS
of the gas flow to a larger second FLS of the gas flow in the
second direction (e.g., Y axis) while the gas flow advances along
the first direction (e.g., X axis). The expansion may be to a FLS
which reduces debris return to the target surface at least during
the operation of the energy beam as part of the 3D printing.
Reduces debris return may be to a degree that is harmful to the 3D
printing process. The flowing gas may form a gas barrier (e.g.,
blanket) above the target surface. In some embodiments, the
expansion of the gas flow may be facilitated and/or limited by (i)
the internal gas flow structure and/or (ii) the outlet opening port
structure. The gas-flow structure may include structural features
within the gas inlet portion, the gas outlet portion, or both. In
some embodiments, the gas inlet portion of the enclosure (e.g., of
the processing chamber) includes a channel (e.g., straight or
winding) configured to facilitate the gas flow therein (e.g., gas
flow expansion (e.g., homogenous expansion)) in at least one
dimension. The channel may comprise a straight section. The channel
may comprise a curved section. In some embodiments, the gas flow
structure (e.g., within the gas inlet portion) expands and shapes a
gas flow volume in order to form a (e.g., substantially) planar
shaped sheet (which can also be referred to as a layer or blanket)
of gas over a target surface. The gas-flow structure may comprise
one or more baffles that form one or more walls that guide and at
least partially define the channel. The gas-flow structure may be
an integral part of the processing chamber, or can be controllably
and/or reversibly engaged with the processing chamber. The flow of
gas above the target surface may form, in the main portion of the
processing chamber, an area of faster gas flow that is adjacent to
the target surface, and slower gas flow in an area that is further
away from the target surface.
[0318] In some embodiments, the gas inlet portion comprises one or
more baffles which alter the velocity, direction, and/or volume of
the gas as it flows along the baffles. For example, the baffles can
slow down and expand the gas flow that enters from a gas inlet
port. The baffles may include one or more walls (which can also be
referred to as partitions, separators, barriers, or dividers) which
can collectively form one or more channels that facilitate (e.g.,
guide) the gas flow (e.g., in a continuous manner) from the inlet
port to the outlet port of the gas inlet portion. The channel can
be a covered channel. In some embodiments, the gas inlet port
corresponds to an opening, or a number of openings, within a wall
of the gas inlet portion. The gas inlet port can be operationally
coupled to one or more gas sources, which may or may not be
operationally coupled to a gas recycling system, e.g., as described
herein. The baffles may include at least one surface (e.g., wall
surface) that is different (e.g., (e.g., substantially)
non-parallel) to the target surface and/or the surface (e.g.,
support surface) of the platform. After entering the gas inlet
port, the gas can move (e.g., and expand) in at least one direction
(e.g., in X, Y, and/or Z direction) as it moves toward a main
portion of the enclosure (e.g., of the processing chamber). In some
cases, the gas moves and expands in accordance with at least one
plane (e.g., in XY, YZ, and/or XZ planes). In some embodiments, the
baffles within the gas inlet portion directs the direction(s) of
gas flow. In some embodiments, walls of the baffles are
particularly oriented with respect to a direction of gas flowat the
gas inlet port. In some embodiments, the baffles are vertically
oriented such that surfaces of the baffles are (e.g.,
substantially) perpendicular with respect to a direction of gas
flow at the gas inlet port, thereby reducing the flow of gas in
along a plane (e.g., a YZ plane). In this way, the baffles can be
configured to increase certain directional components (e.g., X, Y
and/or Z components) of the gas flow within the gas inlet portion.
In some embodiments, walls of the baffles are horizontally oriented
with respect to a direction of gas flow at the gas inlet port. In
some embodiments, the baffles are (e.g., substantially) parallel
with respect to a direction of gas flow at the gas inlet port,
thereby reducing the flow of gas along a plane (e.g., a XZ plane).
In some cases, surfaces of the baffles are at (e.g., substantially)
non-perpendicular or (e.g., substantially) non-parallel with
respect to the direction of gas flow at the gas inlet port, thereby
reducing the flow of gas along one or more planes (e.g., XY, YZ
and/or XZ) to some degree.
[0319] The baffles can be oriented so as to reduce a gas expansion
in a direction toward a material bed (e.g., in the X direction).
For example, in FIG. 21, baffles 2115 are oriented (e.g.,
substantially) perpendicular with respect to the inflow (in the
direction of the arrow above numeral 2116) of gas at inlet 2116.
The baffles can be configured to spread the flow of gas (e.g.,
homogenously) as it flows within the gas inlet portion to provide
an evenly distributed flow of gas (e.g., as it exits the inlet
portion 2114 and forms gas flow 2119) over a target surface (e.g.,
an exposed surface of the material bed). The baffles and/or gas
flow (e.g., gas pressure, etc.) at the gas inlet portion, may be
configured and/or adjusted to facilitate gas flow over a surface
(e.g., 2120) of a material bed (e.g., 2113) in a way that minimally
alters the surface of the material bed. The baffles and/or gas flow
at the gas inlet portion may be configured and/or adjusted to
facilitate a gas flow trajectory, velocity, chemical makeup, or
temperature of the gas flow. For example, the trajectory and/or
velocity of the gas flow that is expelled from the inlet portion
(e.g., comprising the baffle(s)), may minimally alter the target
surface. For example, a temperature of the baffle(s) may adjust
(e.g., heat or cool) during passage of the gas flow adjacent
thereto. For example, a temperature of the gas flow may adjust
(e.g., heat or cool) during its passage through the aligning
structure. The geometry, temperature, and/or chemical
characteristics of the channel (e.g., defined by baffles 2115) may
be adjustable. The adjustment may be before, after, and/or during
at least a portion of a 3D printing operation (e.g., during a
period when the energy beam 2108 irradiates material bed 2113, or
when no energy beam irradiates a material bed 2113). The adjustment
may be controlled manually and/or automatically (e.g., using a
controller). In some embodiments, the baffles are exchangeable,
movable, expandable, and/or contractible. In some cases, the
baffles are heated and/or cooled. In some embodiments, the baffles
comprise a desiccant (e.g., molecular sieves or silica). The
desiccant may be covalently bound, or adhered, to the baffles. The
desiccant may be embedded in a matrix that is casted onto surfaces
of the baffles. In some cases, the channel formed by the baffles
may be operatively coupled to one or more sensors (e.g., humidity,
temperature, and/or oxygen sensors) for measuring characteristics
of the gas flow within the gas inlet portion. The channel may be
operatively coupled to one or more sensors (not shown). The one or
more sensors may comprise humidity, temperature, or oxygen
sensors.
[0320] The orientation of the baffles can alter the flow of gas
within the channel (e.g., formed by gaps between surfaces of the
baffles). For example, the baffles can be configured to reduce a
velocity and/or turbulence of the gas flow, e.g., by their relative
orientation and/or surface makeup (e.g., roughness). In some
embodiments, at least one of a plurality of gaps between baffles
can be adjustable (e.g., before, after, and/or during at least a
portion of a 3D printing operation; e.g., which adjustment can be
controlled by manually and/or automatically by adjusting the
position of one or more baffles. FIG. 22 shows an example of a
perspective view of parts of a gas inlet portion 2200. The gas
inlet portion 2200 of FIG. 22 may correspond to gas inlet portion
2114 of FIG. 21. Gas inlet portion 2200 includes baffles 2202 that
direct gas flow 2204 coming in from inlet port 2206 (which can be
located in wall 2212 of gas inlet portion 2200 and/or in an
enclosure wall of the 3D printing system), and expanding along an X
direction toward outlet port 2210. The outlet port may comprise of
one or more holes (e.g., a perforated plate). For example, gas flow
2204 can flow through gaps 2207 between baffles 2202 before exiting
outlet port 2210. The gaps 2207 can correspond to parts of a
channel through which gas flows within gas inlet portion 2200.
Surfaces of at least two of baffles 2202 (e.g., all the baffles
2202) can be arranged substantially perpendicular (e.g.,
perpendicular) with respect to the direction of inflow of gas 2204
at inlet 2206 (e.g., substantially parallel (e.g., parallel) to the
YZ plane, or substantially perpendicular (e.g., perpendicular) to
the XY plane), and/or with respect to each other. The respective
arrangement of the baffles may be for restricting gas flow along
the X direction and/or distribute expansion of gas 2208 along the Y
and/or Z directions. Such expansion of the gas flow (e.g., along
the Z direction) can provide a homogenous (e.g., and at times
laminar) gas flow over the target surface. The flow of gas in the
channel may alter (e.g., reduce) a velocity and/or turbulence of
the gas flow 2208. In some embodiments, at least two of the baffles
2202 (e.g., all the baffles 2202) are arranged parallel with
respect to each other. In some embodiments (not shown), at least
two of the baffles (e.g., all the baffles) are arranged in
orientations that are non-parallel to each other. In some
embodiments (not shown), at least two of the baffles (e.g., all the
baffles) are arranged parallel with respect to the YZ plane and or
the XY plane. In some embodiments (not shown), at least two of the
baffles (e.g., all the baffles) are arranged in a non-perpendicular
or a non-parallel angle (e.g., planar or compound) with respect to
each other and/or to the XY, YZ and/or XZ planes.
[0321] The size, shape, and number of baffles can vary depending on
a number of factors such as gas flow velocity and/or design
constraints. The outlet port (e.g., 2210) can restrict gas flow
along to Y direction so as to provide a planar-shaped flow of gas
(e.g., 2208) as it exits outlet port . In this way, the gas inlet
portion can provide a sheet or blanket of gas over a target
surface. In some cases, the outlet port corresponds to an elongated
opening in accordance with a (e.g., substantially) planar shape
over a target surface (e.g., elongated with respect to Z axis in
FIG. 22). For example, the outlet port 2210 can have a greater
width than height (e.g., greater width w than height h in FIG. 22).
In some embodiments, a width (e.g., w in FIG. 22) is in accordance
with an FLS (e.g., diameter or width) of the target surface (e.g.,
an exposed surface the material bed). In some embodiments, the
width is greater or less than a FLS (e.g., diameter or width) of an
exposed surface the material bed. In some embodiments,
width-to-height ratio (e.g., w/h) is at least about 1, 1.5, 2, 5,
10, 15, 20, or 50. In some cases, the outlet port is within an
outlet port section (which may be referred to as an "gas outlet
port section", "gas exit port section" or "exit port section"
herein) of the gas inlet portion. In some cases, the outlet port
section corresponds to a subsection of the gas inlet portion having
an elongated shape in accordance with an elongated shaped outlet
port. The outlet port section located at a location of the gas
inlet portion proximate to the target surface. FIG. 22 shows an
example of an outlet port section 2209, which includes and outlet
port 2210, in accordance with some embodiments. Outlet port section
2209 (and gas exit port 2210) can be located at a portion (e.g.,
the bottom) of the inlet portion 2200 (i.e., near to a material
bed). The degree of expansion or compression of a gas within the
gas inlet portion can be characterized by a ratio of a size (e.g.,
cross section area) of the inlet port (e.g., 2206) of the gas inlet
portion relative to a size (e.g., cross section area) of the outlet
port (e.g., 2210) of the gas inlet portion. In some embodiments, a
cross sectional area of gas flow expands or compresses by at least
a prescribed degree by the time it exits the outlet port of the gas
inlet portion. In some embodiments, the cross sectional area of
outlet port (e.g., 2210) is at least about 5%, 10%, 15%, 20%, 25%,
or 30% greater than the cross sectional area of the inlet port
(e.g., 2206) of the gas inlet portion (e.g., 2200).
[0322] In some embodiments, the flow dynamics of the gas as it
exits a gas inlet portion and directed over a target surface, is
controlled. For example, a turbulence of the flow of gas (e.g.,
2208) from the gas exit port (e.g., 2210) can be reduced using a
flow aligning structure (also referred to herein as flow aligner).
The flow alignment structure can be more proximate to the platform
than the baffle(s). The flow alignment structure can be more
proximate to the outlet port (e.g., 2210) of the gas inlet portion
than the baffle(s). The flow alignment structure can direct gas
within the gas inlet portion toward the outlet port or include the
outlet port. In some embodiments, the flow aligning structure is
part of (e.g., within) an outlet port section (e.g., 2209) of the
gas inlet portion. The outlet port section can have an elongated
shape (e.g., in accordance with an elongated shape of the outlet
port. FIGS. 32A and 32B show examples of perspective views of flow
aligning structures 3200 and 3220, respectively, in accordance with
some embodiments. The flow aligning structure (e.g., 3200 or 3220)
can include flow aligning walls (e.g., 3202 or 3222) (which can be
referred to as walls, partitions, separators, dividers, or other
suitable term), which walls can at least partially define flow
aligning passages (e.g., 3204 or 3224) that are configured to allow
gas to flow therethrough. The flow aligning passages can be
referred to as channels, tunnels, elongated holes, elongated
openings, conduit, pipe, tube, or other suitable term. The flow
aligning passages can run lengthwise in accordance with a flow gas
(e.g., in the X direction in FIGS. 21, 22, 32A, and 32B) such that
flow aligning walls (e.g., 3202 or 3222) can reduce gas flow
widthwise and/or height-wise (e.g., in Y and Z directions in FIGS.
21, 22, 32A, and 32B), thereby channeling gas flow along their
lengthwise direction (e.g., in the X direction of FIGS. 21, 22,
32A, and 32B (e.g., direction 3206 or 3226 respectively)). The
walls of the flow aligning structure can align different portions
of the flow gas in accordance with a desired direction (e.g., X
direction). The length of the flow aligning structure (e.g., l in
each of FIGS. 32A and 32B) can vary. In some embodiments, length of
the flow aligning structure (e.g., comprising the flow aligning
channels) is in accordance with a length of the gas exit port
(e.g., 2209 of FIG. 22). In some embodiments, a height (e.g.,
designated "h" in FIG. 22) of the flow aligning structure (e.g., as
measured from a top of the target surface (e.g., material bed) to a
top of the flow aligning structure) is at most about 5'' (inches),
4'', 3'', 2'', 1'', or 0.5''. In some embodiments, the height of
the flow aligning structure ranges between any of the
afore-mentioned heights (e.g., between 0.5'' and 5'', between 0.5''
and 3'', or between 3'' and 5''). The number and shape of the
channels of the flow aligning structure can vary. In some
embodiments, flow aligning passage has a polygonal (e.g.,
hexagonal) cross sections (e.g., as shown in the example of FIG.
32A). The polygon may be a space filling polygon. The flow aligning
passage may comprise a prism, a cone, or a cylinder. The prism may
comprise a polygonal cross section (e.g., any polygon described
herein). The flow aligning passages can (i) have a cross section
that facilitates, and/or (ii) can be packed in, a space-saving
configuration that maximizes the cross-sectional area of flow
aligning passages (e.g., in a direction perpendicular to the
direction of flow). In some embodiments, the flow aligning passage
may have a round cross section (e.g., as shown in FIG. 32B, 3226),
thereby forming flow aligning passage having corresponding round
cross sections (e.g., a cylindrical shaped passage)--which may be
packed in a space saving configuration (e.g., cubic closed packed,
a.k.a., face-centered cubic configuration). In some embodiments, a
ratio of the total cross sectional area of flow aligning passages
is at least about 80%, 85%, 90%, 94%, 95%, 96%, 98, or 99% of a
respective total cross sectional area of the flow aligning
structure (e.g., which includes the thicknesses of the flow
aligning walls). It should be noted, that the flow aligning
structures described herein is not limited to honeycomb shaped or
cylindrical shaped flow aligning walls and/or passages. That is,
the flow aligning structures can have flow aligning walls and/or
passages having any suitable 3D shape or combination of shapes
(e.g., polyhedron, prism, cone (e.g., having an elliptical base,
e.g., circular base), cylinder (e.g., right elliptical cone, e.g.,
right circular cone), pyramid (e.g., having a polygonal base), or
any combination thereof). For example, the flow aligning walls
and/or passages can have any suitable 3D or cross-sectional shape
described herein with reference to FIGS. 10A-10D. Furthermore, flow
aligning structures described herein can have any suitable number
of passages (e.g., channels), and walls having any suitable
thickness. In some embodiments, the flow aligning structure
comprises a substantially two-dimensional structure that amounts to
a mesh structure or plate that includes perforations (i.e., a
perforated plate) for allowing gas to flow therethrough. In some
embodiments, more than one flow aligning structure is used in
combination.
[0323] The one or more channels in the aligning structure may be
configured and/or adjusted to facilitate a gas flow trajectory
(e.g., alignment), velocity, chemical makeup, or temperature of the
gas flow. The velocity and/or trajectory may of the gas flow
expelled from the aligning structure may minimally alter the target
surface. For example, a temperature of the one or more channels may
adjust (e.g., heat or cool) during passing of the gas flow adjacent
thereto. For example, a temperature of the gas flow may adjust
(e.g., heat or cool) during its passage through the aligning
structure. The adjustment may be before, after, and/or during at
least a portion of a 3D printing operation (e.g., during a period
when the energy beam irradiates material bed, or when no energy
beam irradiates a material bed). The adjustment may be controlled
manually and/or automatically (e.g., using a controller). In some
embodiments, one or more channels in the aligning structure are
exchangeable, movable, expandable, and/or contractible. In some
cases, the one or more channels are heated and/or cooled. In some
embodiments, the one or more channels comprise a desiccant (e.g.,
molecular sieves or silica). The desiccant may be covalently bound,
or adhered, to an interior surface of the one or more channels. The
desiccant may be embedded in a matrix that is casted onto the
internal surface of the one or more channels. In some cases, the
one or more channels may be operatively coupled to one or more
sensors (e.g., humidity, temperature, and/or oxygen sensors) for
measuring characteristics of the gas flow within the aligning
structure. The one or more channels may be operatively coupled to
one or more sensors. The one or more sensors may comprise humidity,
temperature, or oxygen sensors.
[0324] In some embodiments, the gas inlet portion of a 3D printing
system has features that control the direction of flow of gas with
respect to the target surface and/or optical window. For example,
the flow of gas from the gas inlet portion can be directed parallel
to, or angled toward or away from the target surface. FIG. 28 shows
an example of a gas flow model 2800 indicating gas flow within an
enclosure for an inlet portion that angles airflow toward a target
surface in accordance with some embodiments; an enclosure 2802
having a gas inlet 2804 directing gas flow 2810 towards the target
surface 2808, two gas outlets 2812 and 2806, a volume having cross
section 2816 in which the gas (mainly) flows above the target
surface 2808 ; a gas inlet 2813 directing gas flow towards the
optical window 2814 that exits the enclosure from a gas outlet
2815. In the example shown in FIG. 28, gas flow model 2800
indicates the directionality (flow lines) and velocity (flow line
darkness) of gas flow within an enclosure 2802. The flow of gas can
enter an enclosure via gas a gas inlet portion and exit the
enclosure via at least one gas outlet portion. The as inlet portion
can be configured to direct the flow of gas to form a blanket above
the target surface. This can be accomplished, for example, by
positioning a gas entry port a distance above the target surface
(e.g., in Y direction) and/or providing a directing passage (e.g.,
having angled walls e.g., 2811) that are angled toward the target
surface. The directing passage may be configured to facilitate a
(e.g., laminar, or non-turbulent) directional gas flow above (e.g.,
and (e.g., substantially) parallel to) the target surface that
flows from one side of the enclosure to an opposing side of the
enclosure. In some embodiments, the gas inlet port is at a
different vertical position that the gas outlet port, which outlet
and inlet ports are disposed at opposing side of the enclosure. In
some embodiments, the gas inlet port is more vertically distant
from the target surface (e.g., or bottom of the enclosure) than the
gas outlet port. In some cases, this configuration can provide some
advantages over having the inlet port at the same vertical distance
from the target surface (e.g., or from the bottom of the enclosure)
as the gas outlet, which outlet and inlet ports are disposed at
opposing side of the enclosure. In some cases, this configuration
can provide some advantages over having the inlet port that
directly faces the outlet port, which outlet and inlet ports are
disposed at opposing side of the enclosure. The gas flow toward the
target surface can, in some embodiments, mitigate a reduction in
flow velocity over the target surface due to the expansion of the
gas during flow. In some cases, directing the gas flow initially
toward a target surface can create a more confined flow path over
the target surface, thereby sustaining some of the flow velocity. A
shown in the example of FIG. 28, the directionality of flow lines
over the target surface can be (e.g., substantially) linear,
indicating regular velocity (e.g., substantially no turbulence) and
a (e.g., substantially) uniform (e.g., laminar) flow. The velocity
of gas flow toward and over the target surface can be within ranges
described herein. In some embodiments, a backflow gas outlet
portion (e.g., 2812) is positioned proximate to the gas inlet
portion (e.g., 2804). The backflow gas outlet portion may
facilitate(i) removal of backflow of gas from the enclosure (e.g.,
2802) and/or (ii) reduce likelihood of turbulence and/or standing
vortices at least in the area above the target surface. In some
cases, the backflow outlet is operationally coupled to a vacuum
source (e.g., pump) to pull the backflow of gas (e.g., and
maintaining in the enclosure pressure at ambient pressure or at
above ambient pressure). For example, using a light vacuum force.
In some embodiments, an optical window purge gas flow (e.g., 2813)
can be used to reduce an amount of debris (e.g., from particles of
the material bed) from reaching the optical window (e.g., 2814),
which will be described in detail herein.
[0325] In some embodiments, the gas outlet portion (e.g., gas
outlet portion 2117 of FIG. 21) can include features that
facilitate a smooth outlet of gas from the processing chamber of
the 3D printing system. FIGS. 30A-30D show schematic views of an
example gas outlet portion 3000 in accordance with some
embodiments. FIG. 30A shows an example of a schematic side view of
gas outlet portion 3000, which channels a gas flow 3003 away from a
processing chamber (not shown) to outlet port 3001. The gas outlet
portion can narrow a (e.g., vertical) cross section of the gas flow
from the inlet port of the channel to the outlet port of the
channel in a gradual manner. The gradual manner may comprise an
aerodynamic manner. The gradual manner may reduce likelihood of
standing vortices and/or turbulence at least above the target
surface and in the processing cone. The gradual manner may reduce
likelihood of debris return to the target surface at least during
the operation of the energy beam (e.g., as part of the 3D
printing). For example, the gas outlet portion can narrow from a
first cross section area (e.g., as indicated by first section line
3004) to a second cross section area (e.g., as indicated by second
section line 3006) to a third cross section area (e.g., as
indicated by second section line 3008). A tapered shape of the gas
outlet portion can be configured to converge the flow toward the
outlet port (e.g., 3001). The gas outlet portion can have features
that reduce an amount of gas flow turbulence during the
convergence, thereby reducing the occurrence of backflow back into
the processing chamber (e.g., opposite direction of gas flow 3003).
For example, in some embodiments, at least a portion of the wall
(e.g., 3002) (also referred to herein as a side) of the gas outlet
portion has a continuous curved interior surface (e.g., 3005) to
facilitate the smooth flow of gas (e.g., aerodynamic shape). In
some embodiments, one side (e.g., top) of the gas outlet portion
tapers more than an opposing (e.g., bottom) side. For example, a
cross-section shape of one side (e.g., 3002) (e.g., top) can be
characterized as having a greater slope than that of a
cross-section of the opposing side (e.g., 3010) (e.g., bottom). A
bottom side of the gas outlet portion can be more proximate to the
platform than the top side.
[0326] In some embodiments, the cross section of the gas outlet
portion is reduced in a prescribed manner. For example, FIGS.
30B-30D show examples of various schematic cross section views of
an example gas outlet portion 3000 at first 3004, second 3006, and
third 3008 section lines. At a first cross section (e.g., 3004)
near the processing chamber, the gas outlet portion can have a
first shape (e.g., a polygonal shape (e.g., square or rectangle)
characterized as having a first area (e.g., yz)). In some
embodiments, the shape and size of the first cross section (e.g.,
3004) is in accordance with a size and shape of a cross section of
the processing chamber (e.g., the same or substantially the same).
At a second cross section (e.g., 3006) nearer to the outlet port
(e.g., 3001) can have a height (e.g., y dimension) that is reduced
(e.g., by a) compared to the first cross section, thereby reducing
an area of a cross section of the gas outlet portion to a second
area (e.g., (y-a)z)). This area reduction can occur smoothly (e.g.,
continuously) over a first distance (e.g., d1). At a third cross
section (e.g., 3008), the height (e.g., y dimension) and width
(e.g., z dimension) of gas outlet portion is reduced (e.g., by b)
over a second distance (e.g., d2), thereby reducing an area of the
cross section of the gas outlet portion to a third area (e.g.,
(y-b)(z-c)). In some embodiments, the third cross section of the
gas outlet portion can be modified to a round shape--thus, the y-b
and z-c dimensions can be the same and each correspond to a
diameter. In some embodiments, the gas outlet portion is comprised
of different pieces. For example, a first piece can comprise walls
that taper from the first cross section to the second cross
section, and a second piece can comprise walls that taper from the
second cross section to the third cross section. In some cases, a
step-wise transition from a polygonal cross section (e.g., square
or rectangle) to a cross section comprising a curvature (e.g.,
circle or oval) can reduce the occurrence of turbulence, standing
vortices, and/or backflow near the target surface. For example, the
second cross section shape can have the same number of sides as the
first cross section shape, while the change to a round shape at the
cross section can occur less proximate to the processing chamber.
In some embodiments, the bulk of the reduction in cross section
area occurs from the transition between the first cross section and
the second cross section. In some embodiments, the third cross
section area is at most about 20%, 15%, 10%, 5%, 3%, 2%, 1%, or
0.5% of the first cross section area. In some embodiments, the
third cross section area relative to the first cross section area
ranges between one or more of the above-referenced percentages
(e.g., from 0.5% to 20%, from 1% to 5%, from 2% to 5%, from 2% to
20%, from 10% to 20%, etc.). In some embodiments, the third cross
section area is at least about 50%, 55%, 60%, 65%, 70%, 75%, 80%,
85%, 90%, 95%, or 99% relative to the first cross section area. In
some embodiments, the third cross section area relative to the
first cross section area ranges between one or more of the
above-referenced percentages (e.g., from 50% to 90%, from 80% to
99%, from 80% to 95%, from 60% to 90%, from 85% to 99%, etc.). In
some embodiments, the first and third distances is at least about
0.1 cm, 0.5 cm, 1 cm, 5 cm, 100 cm, 500 cm, 750 cm, or 1000 cm.
[0327] In some embodiments, the outlet of the gas outlet portion is
configured to promote a vertical (e.g., downward) directional
component of gas flow as the gas exits the enclosure of a 3D
printing system. FIG. 31 shows a schematic side view of an example
gas outlet portion 3100 in accordance with some embodiments, having
a gas outlet portion having a wall 3102, a first interior surface
3105, a second interior surface 3108, an inlet port 3103, and
outlet port 3101, and a gas flow 3106. The gas outlet portion can
include a wall, which includes a first interior surface (e.g., top
surface) and a second interior surface (e.g., bottom surface). In
some embodiments, the first interior surface comprising a
curvature. The first interior surface can be a continuously curved
shape. The first interior surface may be configured to (e.g.,
smoothly) guide the gas flow in a direction away from a processing
chamber of the 3D printing system and/or towards the outlet port
(e.g., 3101). The first interior surface can comprise a curvature
so as to increase a vertical direction component (e.g., in
accordance with they in FIG. 31 (e.g., downward)) of the gas flow,
toward the outlet port . The outlet port can correspond to an
opening that is operatively coupled to a pump. The pump may be part
of a gas recycling system (e.g., as described herein). The outlet
port can be positioned within or as part of the second interior
surface (e.g., bottom surface) of the wall of the gas outlet
portion. The outlet port position may be configured (e.g.,
positioned) to promote a continuous vertical direction component
(e.g., in they direction in FIG. 31) (e.g., downward) of the air
flow within the gas outlet portion. In some embodiments, a first
section (e.g., 3102) of the gas outlet portion can comprise walls
that tapers from a first cross section (e.g., 3114) area to a
second cross section (e.g., 3116) area, and a second piece (e.g.,
3112) of the gas outlet portion can comprise walls that taper from
the second cross section (e.g., 3116) area to a third cross section
(e.g., 3118) area. In some cases, the transition is in a step-wise
fashion, e.g., from a polygonal cross section (e.g., square or
rectangle) to a curved shaped cross section (e.g., circle or oval),
such as described herein with reference to FIG. 30. In some cases,
the first piece and the second piece combine to a form wall (e.g.,
3102) that combine to form a continuously curved interior surface
(e.g., 3105).
[0328] As described herein, gas-borne debris (e.g., soot or powder)
may be present in a processing chamber during a 3D printing
operation. In some cases, the gas-borne debris can interfere with
the efficacy of the energy beam (e.g., laser or electron beam) used
to transform pre-transformed material of a material bed. For
example, the gas-borne debris can encroach an area near a window
(sometimes referred to as an optical window) through the energy
beam passes into the processing chamber, and/or can deposit on an
internal surface of the window. The debris can attenuate the power
density of the energy beam as it travels in towards the target
surface. In some embodiments, the 3D printing systems described
herein include structures and/or mechanisms to reduce an amount of
gas-borne debris near one or more optical windows and/or adhere
thereto. FIG. 23 shows a schematic view example of a 3D printing
system 2300 having a recessed optical window area in accordance
with some embodiments. 3D printing system 2300 includes processing
chamber 2302, which together with build module 2304 form an
enclosure for enclosing material bed 2313 and facilitate the 3D
printing process using the energy beams 2308 and 2309 generated by
energy sources 2306 and 2307 respectively, which energy beams
travel through optical windows 2323 and 2334 towards the target
surface 2320 through an interior 2327 of the processing chamber, to
facilitate formation of the 3D object 2321. In the example shown in
FIG. 23, the processing chamber comprises an inlet portion 2314
having an inlet port 2316, baffles 2315, and an outlet port through
which gas 2319 flows above the target surface 2320 to the outlet
portion 2314, and exits through the outlet port 2318 of the outlet
portion 2317. In some cases, the inlet portion and/or the outlet
portion can include one or more filters (e.g., HEPA filters), as
described herein. The filter(s) may be coupled to a wall of the
enclosure. The filter(s) may control an amount of gas flow (e.g.,
2319). In some embodiments, the filter includes a screen (e.g.,
separating the inlet portion and/or the outlet portion from the
processing chamber).
[0329] The 3D printing system can include at least two energy beam
sources: a first energy beam source and a second energy beam source
which are each configured to generate corresponding energy beams.
Optical mechanisms can be used to control aspects of the energy
beams (e.g., their translation). For example, the optical
mechanisms can control the trajectories of the respective energy
beams through respective optical windows (which can also be
referred to as windows), into the processing chamber, and to a
target surface. In some embodiments, the first and second energy
sources are configured to generate energy beams. The energy beams
may be different in at least one energy beam characteristics. The
energy beams may be the same in at least one energy beam
characteristics. In some embodiments, the first and second energy
beams are used together (e.g., sequentially and/or in parallel)
during printing of a single layer of transformed material. In some
embodiments, the first energy beam can be used to form a first
layer of transformed material and second energy beam can be used to
form a second layer of transformed material that is different than
the first layer. FIG. 23 shows an example of optical mechanisms
2310 and 2311 (e.g., scanners), and optical windows 2323 and 2334
that are each disposed within its own recessed portion, e.g. 2328
and 2324 respectively. In the example shown in FIG. 23, the optical
windows are disposed in a first recess portion 2325 having a
recessed chamber wall 2326 that defines a cavity 2325, the optical
windows 2323 is disposed in a second recess portion 2328 (also
referred to herein as "window holder"), and the optical window 2324
is disposed in a second recess portion 2329 (also referred to
herein as "window holder"). FIG. 23 shows an example of an
optionally backflow current 2333 in the processing chamber interior
volume 2327.
[0330] In some embodiments, the optical window is situated within a
(e.g., first) recessed portion that is coupled to, or is part of
the processing chamber. The recessed portion can include a recessed
chamber wall that at least partially defines a cavity (e.g., a
volume). In some embodiments, one or more optical windows are
disposed within the recessed portion (e.g., within the walls of the
cavity). In some embodiments, the optical window can be further
recessed from the cavity (e.g., by an additionally recessed
portion, e.g., by a second recessed portion). The recessed portion
may be disposed between the windows and the target surface. For
example, the processing chamber can have a recessed wall (e.g.,
ceiling). The recessed portion (e.g., first and/or second) may be
operatively coupled (e.g., connected) to the processing chamber.
The connection may be reversible. The optical window and/or
recessed portion may be exchangeable. In some embodiments, the
recessed chamber wall is integral with other walls of processing
chamber (e.g., forming a continuous chamber wall). The recessed
portion may be an integral part of the processing chamber. In some
embodiments, the recessed chamber wall is a non-integral portion
(e.g., a separable piece) of the processing chamber. The recessed
chamber wall can at least partially surround the cavity to
facilitate reduction in an amount of gas flow from entering therein
(e.g., from the interior of the processing chamber (e.g., 2327)
and/or from the gas flowing above the target surface (e.g., 2319)).
For example, some amount of gas backflow (e.g., circulating gas
flow), turbulence, and/or standing vortex can develop (e.g.,
adjacent to the gas outlet portion), which may include gas-borne
material. The gas-borne material may include pre-transformed
material (e.g., powder) and/or debris (e.g., as a result of
transforming a pre-transformed material to a transformed material
(e.g., soot)). The recessed chamber wall of the recessed portion
can shield the cavity, and thereby shield the windows, from at
least a portion of the backflow, turbulence, and/or standing
vortex. The recessed chamber wall of the recessed portion can
reduce an amount of gas-borne material (e.g., debris) from entering
the cavity of the recessed portion, and/or accumulate on (and/or
adhere to) the optical window(s). The recessed portion can at
least, in part, shield the windows from gas-borne material (e.g.,
debris (e.g., soot)) and/or gas(es) (e.g., oxidative gases) within
the enclosure from depositing on the windows or otherwise
negatively affecting (e.g., reducing intensity) of the energy
beam(s).
[0331] In some embodiments, the window(s) of a 3D printing system
are disposed (e.g., directly) along the wall(s) of a recessed
portion (See e.g., FIGS. 27A-27C). In some embodiments, the
window(s) are disposed in and further recessed within one or more
secondary recessed portions. In the example shown in in FIG. 23,
second recessed portions 2328 and 2329 support and further separate
windows 2323 and 2324, respectively, with respect to the target
surface. In some embodiments, the walls of the window holders are
integral with the recessed chamber wall. In some embodiments, the
walls of window holders are non-integral portions of the processing
chamber wall (e.g., separable from the recessed chamber wall). FIG.
24 shows an example of a cross section view of a window holder
portion 2400 in accordance with some embodiments. Window holder
2400 can correspond to one or both of window holders 2328 and 2329
in FIG. 23. Window holder 2400 further recesses window 2402 with
respect to a main portion of an enclosure (e.g., enclosure 2302 of
FIG. 23). This recess may reduce (e.g., prevent) the gas-borne
material (e.g., pre-transformed material (e.g., powder) and/or
debris) from flowing adjacent to, adhere to, and/or accumulate on
the window 2402 (e.g., on its interior surface 2416).
[0332] In some embodiments, printing the 3D object comprises
formation of debris. The debris may accumulate on the sides of the
enclosure and/or on the (e.g., optical) window. The accumulation on
the window may reduce transmittance of the energy beam
therethrough. For example, the energy beam may scatter from the
debris and/or absorb in the debris that is accumulated on the
window (e.g., during the printing). In some cases, the amount of
gas-borne material that accumulates on the window(s) is reduced to
(e.g., substantially) negligible amounts (e.g., insubstantial
amount). The effectiveness of the recessed window holders with gas
flow purging can be quantified by conducting an energy beam stress
test. The Energy beam stress test can include measuring a peak
intensity reduction (abbreviated herein as "PIR") of the energy
beam (e.g., laser beam). The PIR can be quantified as a ratio of
the peak intensity of a spot irradiated by the energy beam on a
target surface at various times (e.g., on the footprint of the
energy beam at the target surface). The (e.g., two) various times
can be at the beginning and at the end of a 3D printing operation
(e.g., where one or more layers of pre-transformed material are
transformed). The peak intensity of the footprint can correspond to
the peak intensity used to transform a pre-transformed material to
a transformed material (e.g., to form the 3D object). The PIR can
be calculated using the following equation 1:
PIR = Spot peak intensity average [ Spot peak intensity ( N - N av
+ 1 : N ) ] ##EQU00001##
where N is the number of measurements and N.sub.av is the number of
measurement points that are averaged. In some embodiments, the gas
flow can result in an insubstantial (e.g., (substantially)
undetectable) amount of debris affecting the peak intensity of the
energy beam on the target surface (e.g., exposed surface of the
material bed). The peak intensity of the energy beam may be (e.g.,
substantially) unchanged (e.g., not reduced) after transformation
of at least about 1, 500, 1000, 2,000, 5,000 or 10,000 layers of
pre-transformed material. The layer may have a FLS that corresponds
to the FLS of the platform, e.g., as disclosed herein. The peak
intensity of the energy beam can be (e.g., substantially) unchanged
after transformation of any number of layers of pre-transformed
material between any of the aforementioned number (e.g., from 1
layer to 10,000 layers, from 1 layer to 2,000 layers, or from 2,000
layers to 10,000 layers). The peak intensity of the energy beam may
be (e.g., substantially) unchanged (e.g., not reduced) after
transformation of at least about 3.4 milliliters, 1.7 liters, 3.4
liters, 6.8 liters, 17 liters or 34 liters of pre-transformed
material, respectively. The peak intensity of the energy beam can
be (e.g., substantially) unchanged after transformation of any
volume between any of the afore-mentioned volumes of
pre-transformed material (e.g., from about 3.4 milliliters to about
34 liters, from about 3.4 milliliters to about 6.8 liters, or from
about 6.8 liters to about 10,000 liters). In some embodiments, the
3D printing system lacking a gas purging of the window (e.g., as
disclosed herein) may experience significant reduction in peak
intensity of the energy beam (e.g., due to accumulation of debris
at the window) experienced at the target surface. For example,
after printing about 3.4 liters of transformed material (e.g., that
may correspond to about 1000 layers of the 3D object) as part of
the 3D object (e.g., by transforming a pre-transformed material to
a transformed material and subsequently accumulating debris on the
window), the beam intensity experienced at the target surface will
be reduced to about 1% of the initial beam intensity experienced by
the target surface (e.g., when the window was clean). This is
compared to a (e.g., substantially) undetectable reduction in PIR
using a gas purging window, e.g., as disclosed herein, over the
same number of layers.
[0333] The window holders can include a top portion (e.g., FIG. 4,
2401) that supports the window (e.g., 2402), and side walls (e.g.,
2404) that define a volume (e.g., 2406). The window can be made of
any suitable material configured to allow at least a portion of an
energy beam to pass therethrough. The material can be (e.g.,
substantially) transparent to at least a portion of the wavelengths
of the energy beam. The portion may be at least 50%, 60%, 70%, 80%,
or 90% of the wavelengths. In some cases, the window is comprised
of an optical material having high thermal conductivity, e.g., as
having any value of high thermal conductivity disclosed herein. For
example, a suitable material having a thermal conductivity of at
least (e.g., about) 1.5 W/m.degree. C. (Watts per meter per degree
Celsius) 2 W/m.degree. C., 2.5 W/m.degree. C., 3 W/m.degree. C.,
3.5 W/m.degree. C., 4 W/m.degree. C. , 4.5 W/m.degree. C. , 5
W/m.degree. C., 5.5 W/m.degree. C., 6 W/m.degree. C., 7 W/m.degree.
C., 8 W/m.degree. C. 9 W/m.degree. C., 10 W/m.degree. C., or 20
W/m.degree. C., at 300 K (Kelvin). The material can have a thermal
conductivity ranging between any of the afore-mentioned values
(e.g., from about 1.5 W/m.degree. C. to about 20 W/m.degree. C.,
from about 1.5 W/m.degree. C. to about 5 W/m.degree. C., or from
about 5 W/m.degree. C. to about 20 W/m.degree. C. In some
embodiments, the high thermally conductivity material comprises
sapphire, crystal quartz, zinc selenide (ZnSe), magnesium fluoride
(MgF.sub.2), or calcium fluoride (CaF.sub.2). In some embodiments,
the optical window comprises fused silica. In some embodiments, the
optical window comprises a material having a higher thermal
conductivity than that of fused silica (i.e., about 1.38
W/m.degree. C.). In some cases, one or more lenses are used instead
of, or in combination with, window 2402, which one or more lenses
can focus the energy beam. In some cases, the lens(es) are made of
one or more of the materials listed herein for the optical window.
Some materials may have birefringent properties that make them less
suitable for lens(es) (but still may be suitable for windows). For
example, in some embodiments, those materials having significantly
different coefficients of thermal expansion depending on crystal
orientation may not be as suitable for lens(es) (e.g., magnesium
fluoride (MgF.sub.2), calcium fluoride (CaF.sub.2), and
sapphire).
[0334] The window can have any suitable cross-sectional shape
(e.g., elliptical, round, square, rectangular). The window holder
(e.g., 2400) can include a purging system configured to direct a
flow of gas within the volume (e.g., 2406). The side walls (e.g.,
FIG. 24, 2404) of the window holder (e.g., 2400) can include a gas
outlet opening (e.g., 2408) that can introduce a flow (e.g., 2403)
of gas (e.g., non-reactive gas (e.g., argon, nitrogen, etc.)) into
the volume (e.g., 2406) at least partially defined by the window
holder. This flow of gas can push away debris that approaches an
entrance (e.g., 2420) of the window holder. In this way, this flow
of gas can be referred to as purging flow of gas that purges the
volume between the window and the target surface (e.g., in front of
the window) of debris. The side walls (e.g., 2404) can include an
inner wall (e.g., 2410) that includes the outlet opening (also
referred to herein as an outlet) (e.g., 2408), and an outer wall
(e.g., 2412) that includes an inlet opening (also referred herein
as an inlet) (e.g., 2414). The outlet opening can comprise a slit
(or a plurality of slits), a hole (or a plurality of holes), a
perforated plate, mesh, or any other suitable configuration of
openings, apertures, and/or holes. The inner wall may be separated
from the outer wall to form a passage (e.g., 2418) through which
gas can pass from the inlet to the outlet (e.g., as depicted by
arrows in the passage FIG. 24, 2418). The passage may comprise one
or more baffles. The passage may be devoid of baffles. In some
embodiments, the outlet runs around a circumference of inner wall
(e.g., 2410) (e.g., is an annular-shaped slit). In some
embodiments, the inlet runs around a circumference of inner wall
(e.g., 2410) (e.g., is an annular-shaped slit). The outlet can be
configured to direct the flow of gas in a direction away from the
window (e.g., and towards the target surface). For example, the
(e.g., slit-shaped) outlet can be angled in a way that directs the
flow toward a main region of the processing chamber, e.g., angled
downwards as it opens towards the main volume. The outlet may
comprise a nozzle. The outlet may be devoid of a nozzle. In some
embodiments, the direction away from the window is at an (e.g.,
substantially) acute angle (e.g., a in FIG. 24) with respect to the
internal window surface (e.g., 2416). A direction away from the
window can be, for example, a direction towards the entrance (e.g.,
2420) of the window holder, towards the target surface and/or
towards the platform of the 3D printing system. Put another way, a
direction away from the window includes a vector of flow of gas
that is non-tangential and/or non-parallel to the internal window
surface (e.g., 2416). In some embodiments, the flow of gas comes
from opposing sides of the inner wall (e.g., 2410), and converge
toward a central axis (e.g., 2419) (e.g., have a convergence vector
with a cone-like-shape). The influx of gas into the interior of the
window holder can originate a single (e.g., annular) outlet or from
a plurality of outlets (e.g., arranged along two or more opposing
inner walls of the window holder). In some embodiments, the inner
wall and the outer wall of the window holder define a passage in
which gas can flow through (e.g., 2418). The passage may be a
plenum. Gas can pass from an inlet opening (e.g., 2414) of the
outer wall, through the passage, and through outlet opening (e.g.,
2408) to the inner volume (e.g., 2406) of the window holder. In
some embodiments, a ratio of an area of a cross-section of the
passage (e.g., plenum) to an area of a cross-section of the outlet
is at least a prescribed ratio to provide a flow of gas with high
enough pressure and/or velocity to purge the volume (where the
cross-sections of each of the plenum and the inlet are
perpendicular to the flow of gas within each (e.g., per arrows
within plenum 2418 and within inlet 2408). In particular, the flow
of gas within the window holder can experience a pressure loss due
to turbulence and/or friction of the gas along the internal
surfaces of the passage. There may be a ratio between the cross
section of the gas passing through the passage, and the one passing
through the outlet. The ratio can be a perpendicular cross section
area (e.g., 2421) of the passage (e.g., 2218) with respect to the
direction of gas flow in the passage; to a perpendicular cross
section area (e.g., 2422) of the outlet opening (e.g., 2208) with
respect to a direction of gas flow in the outlet opening. In some
embodiments, this ratio is at most about 15:1, 12:1, 11:1, 10:1,
9:1, 8:1 or less. The perpendicular cross section area 2421 of 2218
with respect to the direction of gas flow can be a horizontal cross
section of the passage. The perpendicular cross section area of the
gas outlet with respect to a direction of gas flow can be a
vertical cross section of the outlet. In some embodiments, at least
two of the plurality of outlets and/or inlets are different. In
some embodiments, at least two of the plurality of outlets and/or
inlets are the same.
[0335] A window holder for supporting a window and/or at least
partially shielding a window from debris can have any suitable
shape (e.g., cylindrical, polyhedron, e.g., prism). For example,
the window may have a first cross-sectional shape, and the window
holder may have the same or a different second cross sectional
shape as the window. The first and/or second cross-sectional shapes
may be a geometric shape (e.g., any polygon described herein). The
first and/or second cross-sectional shapes may comprise a straight
line or a curved line. The first and/or second cross-sectional
shapes may comprise a random shape. FIGS. 26A-26E show cross
section views of window holders having different exemplary shapes
and features in accordance with some embodiments.
[0336] The window holder can have a cylindrical cross-sectional
shape, such as shown in the example window holder 2600 in FIG. 26A.
The window holder can include a top portion (e.g., 2601 that) can
be configured to support a round window. The window holder can
include an inner wall (e.g., 2610) that includes the outlet (e.g.,
2608), and an outer wall (e.g., indicated with dashed lines 2602)
that includes an inlet opening. The inner wall can define a volume
into which gas enters through the outlet. As shown in the example
of FIG. 26A, the inlet can correspond to an annular-shaped slit
within the inner wall. FIG. 26B shows an example window holder
2620, indicating that the window holder can have a polygonal
cross-sectional shape (e.g., rectangular prism), which includes a
top portion (e.g., 2621) that can be configured to support a
rectangular or square cross-sectional shaped window. The window
holder can include an inner wall (e.g., 2630) that includes the
outlet (e.g., 2628), and an outer wall (e.g., indicated with dashed
lines 2622) that can include an inlet. The inner wall can define a
volume that gas enters via the outlet, which can correspond to a
continuous slit through all sides of the inner wall (e.g., 2630).
The cylindrical window holder may hold a polygonal window. The
polyhedron window holder may hold an elliptical (e.g., circular)
window. FIG. 26C shows a window holder 2640, indicating that the
window holder can have a polygonal cross-sectional shape (e.g., as
part of a rectangular prism), which includes a top portion (e.g.,
2641) that can be configured to support a rectangular or square
cross-sectional shaped window. The window holder can include an
inner wall (e.g., 2650) that includes the gas outlet (e.g., 2648),
and an outer wall (e.g., indicated with dashed lines 2642) that
includes the gas inlet. The inner wall can define a volume that gas
enters via the outlet (e.g., 2648), which can correspond to
multiple slits within one or more sides (e.g., opposing sides) of
the inner wall. FIG. 26D shows an example window holder 2660,
indicating that the window holder can have a cylindrical
cross-sectional shape, which includes a top portion (e.g., 2661)
that can be configured to support a round cross-sectional shaped
window. The window holder (e.g., 2660) can include=inner wall
(e.g., 2670) that includes the gas outlet (e.g., 2668), and an
outer wall (e.g., indicated with dashed lines 2662) that includes
the gas inlet. The inner wall can define a volume that gas enters
via the outlet (e.g., 2668), which can correspond to a multiple
holes within the inner wall. FIG. 26E shows an example window
holder 2680, indicating that the window holder can have a polygonal
cross-sectional shape (e.g., as part of a rectangular prism), which
includes a top portion (e.g., 2681) that can be configured to
support a rectangular or square cross-sectional shaped window. The
window holder can include an inner wall (e.g., 2690) that includes
the outlets (e.g., 2688), and an outer wall (e.g., (indicated with
dashed lines 2682) that includes an inlet. The inner wall (e.g.,
2690) can define a volume that gas enters via the outlets (e.g.,
2688), which can correspond to a plurality of holes within one or
more sides of the inner wall. Features of FIGS. 26A-26D can be
combined, where suitable. For example, an inner wall can include
slit(s) and hole(s). A cylindrical cross-sectional shaped window
holder can be configured to support a rectangular or square
cross-sectional shaped window, or vice versa. It should be noted
that the embodiments shown in FIGS. 26A-26D are shown for
illustrative purposes and do not limit the scope (e.g., shape,
size, features) in accordance with embodiments as described herein.
The inlet (e.g., gas inlet) can comprise a plurality of gas inlets.
The outlet (e.g., gas outlet) can comprise a plurality of
outlets.
[0337] An optical window of a 3D printing system can have one or
more window holders, which may or may not be further recessed with
respect to a main portion of an enclosure. To illustrate, FIGS.
27A-27F show schematic example cross section views of various
embodiments of optical window portions (e.g., analogous to FIG. 23,
2325) as part of one or more 3D printing systems in accordance with
some embodiments. FIG. 27A shows an example of an optical window
portion 2700, which indicates that the optical window portion
includes a window holder 2702 that supports the window 2704 and
defines a volume 2706 that is recessed with respect to a wall
(e.g., 2708) of an enclosure. The wall can be a ceiling of the
enclosure. FIG. 27B shows an example of an optical window portion
2710 that includes two window holders 2712a and 2712b that support
windows 2714a and 2714b respectively, and that define volumes 2716a
and 2716b (respectively) that are recessed with respect to a wall
2718 of an enclosure. FIG. 27C shows an example of an optical
window portion 2720 that includes window holders 2722a and 2722b
that support windows 2724a and 2724b (respectively), and that
define volumes 2726a and 2726b (respectively) that are recessed
with respect to a wall 2728 of an enclosure. FIG. 27D shows an
example of an optical window portion 2730 that can include a window
holder 2732 that supports the window 2734 and that defines a volume
2736. The window holder (e.g., 2732) can be further recessed with
respect to the wall (e.g., 2738) of an enclosure by a recessed
portion (e.g., 2731). FIG. 27E shows an example of an optical
window portion 2740 that includes at least two window holders 2742a
and 2742b that support windows 2744a and 2744b (respectively), and
that can define volumes 2746a and 2746b. The at least two window
holders can be further recessed with respect to a wall (e.g., 2728)
of an enclosure by a recessed portion (e.g., 2741). FIG. 27F shows
an example of optical window portion 2750 that includes three
window holders 2752a, 2752b, and 2752c that support windows 2754a,
2754b and 2754c (respectively), and that define volumes 2756a,
2756b and 2756c (respectively); which three window holders are
further recessed with respect to a wall 2728 of an enclosure by a
recessed portion 2751.
[0338] In some cases, the window holders are in an arrangement with
respect to the energy source(s), a flow of gas within the
enclosure, and/or an opening of the enclosure. FIGS. 39A-39C
illustrate top views of various example printing systems. FIG. 39A
show enclosure 3900, which includes processing chamber 3902, gas
inlet portion 3904, gas outlet portion 3906 and an optional
ancillary chamber 3908. The window holders (e.g., 3910 and 3912)
can be aligned (e.g., in accordance with line 3919) that is (e.g.,
substantially) aligned (e.g., parallel) with a direction (e.g.,
3918) of a flow of gas through the enclosure (e.g., above a target
surface and/or platform in the processing chamber). An opening
(e.g., 3916) to the enclosure (e.g., processing chamber) may
provide access to the three-dimensional part, the material bed,
and/or the platform within the processing chamber. The opening may
be used by an operator or a robot. The window holders may be
coupled to energy source(s) and/or associated optics and
controllers. In some embodiments, the window holders (and
associated equipment) are arranged provide easy access to the
opening. In some cases, the window holders are (e.g.,
substantially) aligned (e.g., parallel) with the opening. FIG. 39B
show enclosure 3920, which includes processing chamber 3922, gas
inlet portion 3924, gas outlet portion 3926 and an optional
ancillary chamber 3928. The window holders (e.g., 3930 and 3932)
can be aligned (e.g., in accordance with line 3939) (e.g.,
substantially) orthogonally (e.g., perpendicularly) with a
direction (e.g., 3938) of a flow of gas through the enclosure. In
some cases, the window holders are aligned (e.g., substantially)
orthogonally (e.g., perpendicularly) with the opening (e.g., 3936).
FIG. 39C show enclosure 3940, which includes processing chamber
3942, gas inlet portion 3944, gas outlet portion 3946 and an
optional ancillary chamber 3948. The window holders (e.g., 3950 and
3952) can be aligned (e.g., in accordance with line 3959) at an
angle (e.g., non-parallel and non-orthogonal) with respect to a
direction (e.g., 3958) of a flow of gas through the enclosure. In
some cases, the window holders are aligned at an angle (e.g.,
non-parallel and non-orthogonal) with respect to the opening (e.g.,
3956). The example embodiments shown in FIGS. 27A-27F and 39A-39C
do not limit the scope and number of possible embodiments described
herein. That is the optical window portions described herein can
include any suitable number and arrangement of windows, window
holders, recessed portions, etc., which can each have any suitable
shape and size.
[0339] In some embodiments, the direction of the purging gas flow
for a window can depend on a number of factors, including
structural features of the enclosure, gas flow velocity and gas
flow dynamics. In some embodiments, the purging flow of gas in
front of a window (e.g., between the window and the target surface)
is primarily in one direction, i.e., unidirectional (e.g., flowing
from one side of the optical window to an opposing side of the
optical window). In some embodiments, the purging flow of gas in
front of a window has a primary component in one direction. In some
embodiments, the purging flow of gas in front of a window is has a
primary component in one direction that changes to a primary
component in a second direction (e.g., with the one direction and
second direction forming an angle, e.g., 90 degrees angle). The
angle can be acute, obtuse, or right angle. In some embodiments,
the purging flow of gas in front of a window converges below the
window (e.g., between the window and the target surface). In some
embodiments, the purging flow of gas in front of a window comprises
(i) a flow component in a direction towards the target surface or
(ii) a flow component in a direction parallel to the window. In
some embodiments, the purging flow of gas in front of a window
flows (i) parallel to the window, (ii) perpendicular to the window,
(iii) in a direction different than parallel to the window, (iv) in
a direction different than perpendicular to the window, or (v) any
combination or permutation thereof. In some embodiments, gas
flowing from a plurality positions, flows towards a conversion
point and/or line. At least two positions of the plurality oppose
each other in space (e.g., the gas flowing from the at least two
positions has opposing flow components). FIGS. 29A and 29B show
schematic side views of example 3D printing systems having features
for purging a volume in front of a window using a substantially
unidirectional (e.g., unidirectional) flow component in accordance
with some embodiments. In some embodiments, the flow of purging gas
(e.g., 2918) is directed from a purge inlet (e.g., 2912) to a purge
outlet (e.g., 2914), which can be parallel to an internal surface
optical of the window (e.g., 2916). This configuration can provide
a "blanket" of gas in front of the window. An additional (e.g.,
primary) flow of gas (e.g., 2903) can flow over the target surface
(e.g., 2908) from the gas inlet portion (e.g., 2904) to the gas
outlet portion (e.g., 2906). This can optionally cause a gas flow
recirculation path (e.g., 2905) within the enclosure (e.g., 2902).
In order to alleviate such occurrence, the flow of purging gas
(e.g., 2918) can be in a direction opposite the primary flow of gas
for better flow efficiency. In some embodiments, the purge outlet
is operatively coupled to a vacuum pump to assist the flow of gas
toward purge outlet (in which case, the purge inlet may or may not
be coupled to a pressurized gas source). The enclosure (e.g., 2922
in FIG. 29B) can include a recessed region (e.g., 2927) (e.g.,
recessed portion (e.g., FIG. 23, 2301) or window housing (e.g.,
FIG. 23, 2323 or 2324)). The flow of purging gas (e.g., 2928) can
be directed from the purge inlet (e.g., 2934) to the purge outlet
(e.g., 2932). The flow of purging gas can be parallel to an
internal surface of window (e.g., 2936). The primary flow of gas
(e.g., 2923) can flow over the target surface (e.g., 2928) from the
gas inlet portion (e.g., 2924) to the gas outlet portion (e.g.,
2926). This can cause an optional gas flow recirculation path
(e.g., 2925) within the enclosure (e.g., 2922). Components of the
gas flow recirculation path can reverse direction near the recessed
region (e.g., as shown in FIG. 29B). In such a flow architecture,
the flow of purging gas can be in the same direction as the primary
flow of gas for better flow efficiency. In some embodiments, the
purge outlet is coupled to a vacuum source to assist the flow of
gas toward the purge outlet (in which case, the gas purge inlet may
or may not be coupled to a pressurized gas source). In some
embodiments, the gas flow purge is directed away from or toward the
window (e.g., instead of parallel to the window). In some
embodiments, the pressure in the enclosure may be regulated to
maintain a pressure at or above ambient pressure (e.g., albeit the
coupling to a pressurized source and/or vacuum source).
[0340] In some embodiments, the inner walls of the window holder
(e.g., FIG. 23, 2329) are angled with respect to the window and/or
with respect to each other. In some embodiments, the inner walls of
the window are parallel to each other and/or perpendicular to the
optical window. FIG. 38A shows a cross section view of an example
window holder 3800. The window holder can have side walls (e.g.,
3804) that recesses at least one window (e.g., 3802) and that can
at least partially facilitate shielding the at least one window
from gas-borne debris that may be moving within a main portion of
an enclosure (e.g., enclosure 2302 of FIG. 23). The recess may be
with respect to a wall of the enclosure (e.g., a ceiling, e.g.,
FIG. 23, 2302) to which the recess portion (e.g., 2301) is coupled
to. The wall(s) of the window holder can include an inner portion
(e.g., 3810) that can include the outlet (e.g., 3808). The inlet
and/or the outlet can correspond to a slit (or a plurality of
slits), a hole (or a plurality of holes), a perforated plate, mesh,
or any other suitable configuration of openings, apertures, and/or
holes, as described herein. The slit can be an annular slit. The
outer portion (e.g., 3812) of the wall(s) can include at least one
inlet (e.g., 3814). The walls can include at least one passage
(also referred to herein as a channel) (e.g., 3818) through which
gas can pass from the inlet opening to the outlet opening (e.g., as
depicted by arrows in the passage FIG. 38A). The outlet can be
configured to direct the flow of gas within the inner volume (e.g.,
3806) (also referred to as volume, cavity, or region) of the window
holder in a direction away from the window (e.g., and towards the
target surface). In some embodiments, the inner wall (e.g., 3810)
is at an angle (e.g., a (alpha)) with respect to an inner surface
(e.g., 3803) of the window. In some embodiments the angle (alpha)
is acute. In some embodiments, the angle alpha is obtuse. In some
embodiments, the angle alpha is a right angle. In some embodiments,
the angle is (e.g., substantially) at least about 10.degree.,
20.degree., 30.degree., 40.degree., 45.degree., 50.degree.,
60.degree., 70.degree., 80.degree., 90.degree., 85.degree.,
90.degree., 95.degree., 100.degree., 110.degree., 125.degree.,
150.degree., or 170.degree., or 180.degree.. In some embodiments,
the angle is at most about 10.degree., 20.degree., 30.degree.,
40.degree., 45.degree., 50.degree., 60.degree., 70.degree.,
80.degree., 90.degree., 85.degree., 90.degree., 95.degree.,
100.degree., 110.degree., 125.degree., 150.degree., or 170.degree.,
or 180.degree.. The angle can range between any of the
afore-mentioned degrees (e.g., from about 10 to about 90, from
about 20 to about 90, from about 45 to about 125, from about
85.degree. to about 180.degree., from about 85.degree. to about
110.degree., from about 110.degree. to about 180.degree., or from
about 90.degree. to about) 170.degree.. FIG. 38A shows an example
in which the angle alpha between the inner surface of the window
3803 and the inner wall 3810, is obtuse. The insert 3890 in FIG.
38A shows an example in which the angle alpha between the inner
surface of the window 3891 and the inner wall 3892, is acute.
Insert 3890 shows an optional alternate geometry of a wall (e.g.,
3810) with respect to the window. In some embodiments, two or more
inner walls form an acute angle with the inner surface of the
window. In some embodiments, two or more walls form an obtuse angle
with the inner surface of the window (e.g., 3810 with 3803). In
some cases, the window holder is configured to provide a gas flow
having a downward flow component. Downward may be towards the
platform and/or target surface. Downward may be in a direction away
from the internal surface (e.g., 3803) of the optical window (e.g.,
3802). Downward may be toward the main portion of the enclosure.
The downward flow component may be at a predetermined distance
(e.g., 3820) from the internal surface of the window or greater.
The downward flow component can comprise a vertical flow component.
In some embodiments, the window holder is configured to operate
using a pre-determined pressure of gas flow. In some embodiments,
the pressure is at least about 5 mm/sec (millimeters per second),
10 mm/sec, 20 mm/sec, 50 mm/sec, 100 mm/sec, or 200 mm/sec. In some
embodiments, the flow (e.g., within the window holder) is at a
speed of at most about 500 mm/sec, 300 mm/sec, 200 mm/sec, 100
mm/sec, or 50 mm/sec. The gas flow speed can range between any of
the afore-mentioned speeds (e.g., from about 5 mm/sec to about 500
mm/sec, from about 5 mm/sec to about 100 mm/sec, or from about 100
mm/sec to about 500 mm/sec). In some embodiments, at least one
window holder (e.g., 3821) comprises a ring, bracket, and/or clamp
that can be used to facilitate coupling of the window to the side
walls. In some embodiments, the window holder accommodates one or
more fasteners (e.g., screws, bolts, pins, adhesives, tapes). For
example, the window holder can include holes (e.g., threaded
holes), recesses, protrusions, or ledges. An outer surface (e.g.,
3822) of the window can be non-flush (e.g., recessed or proud) with
respect to an outer surface (e.g., 3824) of the window holder. The
outer surface of the window can be flush (e.g., (e.g.,
substantially) parallel) with an outer surface of the window
holder. In some embodiments, the window holder includes one or more
sensors (e.g., 3825) that is/are configured to detect the presence
of and/or an amount of material (e.g., debris) in a proximity of
the window holder and/or the window. At least one of the sensor(s)
can be positioned within the wall (e.g., 3812) and/or within the
inner volume (e.g., 3806) of the window holder and/or processing
chamber. The sensor(s) can be positioned outside of the inner
volume of the window holder. For example, at least one of the
sensor(s) can be positioned outside the wall (e.g., 3812) and/or
outside the inner volume (e.g., 3806) of the window holder and/or
processing chamber.
[0341] In some cases, at least one optical window (e.g., 115)
and/or its window holder is at least partially incorporated
(directly or indirectly) in a wall of the enclosure. In some cases,
the optical window and/or window holder is at least partially
incorporated in (the wall of) a recessed portion of an enclosure.
FIG. 38B shows an example of a cross section view of a recessed
portion 3850 of an enclosure (e.g., 3852). The walls (e.g., 3853)
of the recessed portion can at least partially define the cavity
(e.g., 3856) (also referred to as a volume or region). The recessed
portion can be integrally formed with the enclosure. The recessed
portion can be coupled (e.g., detachably coupled) with the
enclosure. The one or more window holders (e.g., 3854) can be
positioned within one or more walls (e.g., top wall 3855) of the
recessed portion. For example, the window holder(s) can be
positioned within openings of the wall(s) of the recessed portion
configured to accommodate the window holder(s). In some cases, the
wall(s) of the recessed portion have one or more channels (e.g.,
3862) (also referred to as tunnels or passages) for gas to travel
to the window holder(s). The channel(s) can be operationally
coupled to the inlets of the window holder(s). The channel(s) can
be operationally coupled to one or gas sources and/or one or more
pumps, e.g., as described herein. The channel(s) can provide a
passage for the flow of gas to reach the inlet of the window
holder(s) to purge the region adjacent the window(s) of material
(e.g., debris). In some embodiments, the recessed portion
accommodates one or more sensors (e.g., 3858). The sensor(s) can be
any suitable type of sensor (e.g., camera or detector), e.g., as
described herein. The sensor(s) can be used to detect any suitable
input(s) (e.g., light or temperature). In some embodiments, the
sensor(s) is/are used to detect input parameters(s) from the
processing chamber (e.g., at or near the target surface (e.g.,
exposed surface of the material bed)). In some cases, the sensor(s)
is/are used to detect gas-borne material (e.g., pre-transformed
material, debris, gas contaminants, gas components, and/or reactive
species) within the cavity and/or within a main volume of the
enclosure (e.g., of the processing chamber). In some embodiments,
the sensor(s) is/are configured to sense in a direction (e.g.,
3860) toward the target surface. In some embodiments, the sensor(s)
are used to determine a height and/or uniformity of the target
surface (e.g., exposed surface of the material bed), for example,
as described in International Patent Application number
PCT/US17/18191 filed on Feb. 16, 2017, titled "ACCURATE
THREE-DIMENSIONAL PRINTING," European Patent Application number EP
17156707.6 filed on Feb. 17, 2017, titled "ACCURATE
THREE-DIMENSIONAL PRINTING," U.S. Patent Application Publication
number 2017/0239891 A1, or International Patent Application number
PCT/US15/65297 filed Dec. 11, 2015, titled "FEEDBACK CONTROL
SYSTEMS FOR THREE-DIMENSIONAL PRINTING", each of which is entirely
incorporated herein by reference.
[0342] In some embodiments, a 3D printing system includes, or is
operationally couple to, one or more gas recycling systems. FIG. 25
shows a schematic side view of an example 3D printing system 2500
that is coupled to a gas recycling system 2503 in accordance with
some embodiments. 3D printing system 2500 includes processing
chamber 2502, which includes gas inlet 2504 and gas outlet 2505.
The gas recycling system (e.g., 2503) of a 3D printing system can
be configured to recirculate the flow of gas from the gas outlet
(e.g., 2505) back into the processing chamber (e.g., 2502) via the
gas inlet (e.g., 2504). Gas flow (e.g., 2506) exiting the gas
outlet can include solid and/or gaseous contaminants such as debris
(e.g., soot, particles). In some embodiments, a filtration system
(e.g., 2508) filters out at least some of the solid and/or gaseous
contaminants, thereby providing a clean gas (e.g., 2509) (e.g.,
cleaner than gas flow 2506). The filtration system can include one
or more filters. The filters may comprise HEPA filters or chemical
filters. The clean gas (e.g., 2509) exiting the filtration system
can be under relatively low pressure, and therefore can be directed
through a pump (e.g., 2510) to regulate (e.g., increase) its
relative pressure prior to entry to the processing chamber. Clean
gas (e.g., 2511) with a regulated pressure that exits the pump can
be directed through one or more sensors (e.g., 2512). The one or
more sensors may comprise a flow meter, which can measure the flow
(e.g., pressure) of the pressurized clean gas. The one or more
sensors may comprise temperature, humidity, or oxygen sensors. In
some cases, the clean gas can have an ambient pressure or higher.
The higher pressure may provide a positive pressure within
processing chamber (see example values of positive pressure
described herein). A first portion of the clean gas can be directed
through an inlet (e.g., 2504) of a gas inlet portion of the
enclosure, while a second portion of the clean gas can be directed
to first and/or second window holders (e.g., 2514 and 2516) that
provide gas purging of optical window areas, as described herein.
That is, the gas recycling system can provide clean gas to provide
a primary gas flow for the 3D printing system, as well as a
secondary gas flow (e.g., window purging). In some embodiments, the
pressurized clean gas is further filtered through a filter (e.g.,
2517 (e.g., one or more HEPA filters)) prior to reaching one or
both of the window holders. In some embodiments, the one or more
filters (e.g., as part of filters 2517 and/or filtration system
2508) are configured to filter out particles having nanometer-scale
(e.g., about 10 to 500 nm) diameters. In some embodiments, the gas
recycling system alternatively or additionally provides clean gas
to a recessed portion (e.g., 2518) of the enclosure.
[0343] As described herein, the gas inlet portion of the 3D
printing system can include flow aligning structures that align
(e.g., straighten) the flow of gas as it exits the gas inlet
portion and/or enters the processing chamber. In some embodiments,
the flow aligning structure is not limited to being within an
outlet port section (e.g., 2209 in FIG. 22). To illustrate, FIGS.
33A-33E show schematic cross section views of various examples of
enclosures having different gas inlet portion configurations in
accordance with some embodiments. FIG. 33A shows an example of
enclosure 3300 having processing chamber 3302 (including opening
3305, e.g., for a material bed), gas inlet portion 3304 (including
inlet ports 3301), and gas outlet portion 3306 having an outlet
port 3303. FIG. 33A shows an example of a gas inlet portion that
include multiple flow aligning walls that can define multiple flow
aligning passages (e.g., 3304) and multiple corresponding inlet
ports (e.g., 3301) having tapered shapes (e.g., having polygonal
cross sections near the processing chamber and round or elliptical
cross sections at the outlet port). FIG. 33B shows an example of
enclosure 3320 having processing chamber 3322 (including opening
3325, e.g., for a material bed), gas inlet portion 3324a and 3324b
(including inlet ports 3321a and 3321b respectively), and gas
outlet portion 3326 having an outlet port 3323. FIG. 33B shows that
a gas inlet portion can include multiple flow aligning sections
(e.g., 3324a and 3324b), each having multiple walls that can define
multiple flow aligning passages and multiple corresponding inlet
ports (e.g., 3321a and 3321b). FIG. 33C shows an example of an
enclosure 3340 having processing chamber 3342 (including opening
3345, e.g., for a material bed), gas inlet portion 3344 (including
inlet ports 3341), and gas outlet portion 3346 having an outlet
port 3343. FIG. 33C shows that a gas inlet portion (e.g., 3344) can
include multiple flow aligning walls that can define multiple flow
aligning passages and multiple corresponding inlet ports (e.g.,
3341). FIG. 33D shows an example of enclosure 3360 having
processing chamber 3362 (including opening 3365, e.g., for a
material bed), gas inlet portion 3364 (including inlet ports 3311),
and gas outlet portion 3366 (including outlet port 3363). FIG. 33D
shows that a gas inlet portion (e.g., 3364) can include multiple
flow aligning walls that can define multiple flow aligning passages
and multiple corresponding inlet ports (e.g., 3361) having tapered
cone shapes. FIG. 33E shows an example of enclosure 3380 having
processing chamber 3382 (including opening 3385, e.g., for a
material bed), gas inlet portion 3384a and 3384b (including inlet
ports 3381a and 3381b respectively), and gas outlet portion 3386
having outlet port 3383. FIG. 33E shows that a gas inlet portion
can include multiple flow aligning sections (e.g., 3384a and
3384b), each having multiple walls that can define multiple flow
aligning passages, each having multiple corresponding inlet ports
(e.g., 3381a and 3381b). The example embodiments shown in FIGS.
33A-33E do not limit the scope and number of possible embodiments
described herein. That is the gas inlet portions described herein
can include any suitable number and arrangement of flow aligning
sections, flow aligning walls, flow aligning passages, inlet ports,
etc., which can each have any suitable shape and size.
[0344] It should be noted that the various embodiments of
structures, features, and mechanisms of 3D printing systems
described herein can be combined in any suitable arrangement. For
example, a gas inlet portion can include features that direct gas
flow toward a target surface, e.g., a surface of a material bed
(e.g., FIG. 28); as well as gas flow channeling structures such as
baffles (e.g., FIG. 22) and/or flow straighteners (e.g., FIG. 32)
described herein. As another example, a unidirectional window
purging system (e.g., FIGS. 29A and/or 29b) can be combined in any
suitable way with a window recessed portion and/or a window housing
(e.g., FIGS. 23, 24, 26A-26E, and/or 27A-27F). As another example,
gas outlet portions (e.g., FIGS. 30A-30D and/or 31) can be combined
in any suitable way with any feature of a gas inlet portion (e.g.,
FIGS. 22, 28, 29A-29B, and/or 32). That is, the various advantages
provided by individual structures, features, and mechanisms
described herein can be combined an any suitable way within a 3D
printing system.
[0345] At times, at least one component of the optical system may
be coated (e.g., by accumulation of debris). The coating may absorb
light and/or heat the component. In some embodiments, at least a
portion of the beam path may be enclosed in a casing. The casing
may form a channel for the energy beam to travel therethrough. The
beam path may comprise a path originating from the energy source to
the processing chamber (e.g., to the optical window, inclusive), or
any portion thereof. The beam path may comprise a path originating
from emergence of the generated energy beam to the atmosphere, and
ending at the processing chamber (e.g., ending at the optical
window, inclusive), or any portion thereof. Emergence of the energy
beam to the atmosphere may be emerging from the energy source
collimator (e.g., fiber). The casing may comprise one or more
walls. Enclosure of the beam path may reduce debris from affecting
the beam as it travels through the path. The enclosed beam path may
be purged with at least one gas (e.g., any gas disclosed herein;
which can be referred to as a purging gas or purging gas flow). For
example, the gas may comprise Clean Dry Air, filtered Air, Argon,
or Nitrogen. The gas may be inert. The gas may be non-reactive. At
least one component of the optical system (e.g., mirror or lens)
may be cooled. The cooling may be active (e.g., using circulating
coolant) or passive (e.g., using heat sink). The casing may have at
least one gas inlet and at least one gas inlet. In some
embodiments, the casing may comprise a plurality of gas outlets. In
some embodiments, the one or more walls of the casing may be leaky
(e.g., allow escape of some of the purging gas flow therein via one
or more openings, cracks, an/or apertures). The casing may comprise
a seal. The seal may be leaky, e.g., allow gas lo leak
therethrough. The purging of the casing may be before, after,
and/or during the 3D printing. The purging may be controlled (e.g.,
manually and/or automatically). Th automatic control may comprise
one or more controllers.
[0346] In some embodiments, the layer forming apparatus (also
referred to herein as a material dispensing mechanism, layer
dispenser, or layer forming device) can travel in a direction
relative to a flow of gas within the enclosure. The layer forming
apparatus can be used to form one or more (e.g., substantially)
planar shaped layers of pre-transformed material (e.g., as part of
the material bed). In some embodiments, a printing system includes
one layer forming apparatus. In some embodiments, a printing system
includes multiple layer forming apparatuses. As described herein a
layer forming apparatus can include one or more components, such as
at least one material dispenser, at least one leveler, and/or at
least one material remover. FIGS. 34A and 34B show side and
elevation schematic views, respectively, of example layer forming
apparatuses. The layer forming apparatus can be configured to form
a (e.g., substantially) planar shaped layer(s) of (e.g.,
pre-transformed) material. FIG. 34A shows an example of a layer
forming apparatus (e.g., 3400) that includes a material dispenser
(e.g., 3402), a leveler (e.g., 3403) and a material remover (e.g.,
3404). The material dispenser can be configured to dispense (e.g.,
pre-transformed) material (e.g., 3401), which may be disposed
therein (e.g., within a cavity of the material dispenser). In some
embodiments, the leveler (e.g., comprising a blade (e.g., 3405))
can be disposed between the material dispenser and the material
remover. The layer forming apparatus can be configured to traverse
(e.g., translate) in one (e.g., first) direction (e.g., 3406)
and/or another (e.g., second) direction (e.g., 3407). The first and
second directions can be opposite directions. In some embodiments,
the layer forming apparatus is configured to move in one (e.g.,
first) direction (e.g., 3406) when the material dispenses (e.g.,
pre-transformed) material, and in another (e.g., second) direction
(e.g., 3407) when the leveler levels the exposed surface (e.g.,
3408) of the material bed (e.g., 3409) and/or when the material
remover removes (e.g., via suction) at least a portion of material
bed. The layer forming apparatus can traverse in a direction that
is (e.g., substantially) parallel to a surface (e.g., top surface)
of the platform and/or the target surface. The layer forming
apparatus can provide a uniformly thick layer and condition an
exposed surface of (e.g., level) the material bed prior to, for
example, directing an energy beam at the material bed for forming a
3D object (e.g., 3410). In some configurations, at least one
component of the layer forming apparatus may be connected to at
least one shaft (e.g., 3411). For example, one or more of the
components of the layer forming apparatus may be coupled with
(e.g., connected to) the at least one shaft. The shaft may be
operatively coupled (e.g., connected) to a translating component
(e.g., 3413). The at least one shaft may be operatively coupled
(e.g., connected) to one or more actuators. The one or more
actuators may facilitate (e.g., linear) motion of the shaft (e.g.,
to and from the processing chamber, and/or to and from the
ancillary chamber). The translating component may comprise the
actuator. The linear motion may be in a direction that is (e.g.,
substantially) parallel to a surface (e.g., top surface) of a
platform (e.g., 3412), e.g., that supports the material bed. The
linear motion may be in a direction that is not (e.g.,
substantially) parallel to the surface of the platform. The linear
motion may comprise a component (e.g., be in a) direction that is
(e.g., substantially) perpendicular to a direction of movement
(e.g., FIG. 1, 112) of the platform (e.g., in accordance with an
elevator (e.g., FIG. 1, 105) a build module (e.g., FIG. 1, 123)).
The linear motion may be in a direction that is not (e.g.,
substantially) perpendicular to a direction of movement of the
platform. The actuator may include a motor. For example, the
translating component may be a motor that facilitates linear motion
(e.g., of the shaft and/or of at least one component of the layer
forming mechanism). The motor may be any motor described herein. In
some embodiments, at least two of the material dispensing,
leveling, and material removal is performed synchronously (e.g., in
the same translation cycle). Synchronously may be within a single
translation cycle. A translation cycle may include translating the
layer forming apparatus laterally from one (e.g., first) side of a
(e.g., processing) chamber to another (e.g., second) side of the
(e.g., chamber. A translation cycle may include translating the
layer forming apparatus laterally from one (e.g., first) end of the
material bed to another (e.g., second) end of the material bed. An
end of a material bed may be a position on the periphery of the
material bed. In some embodiments, at least one of the components
of the layer forming apparatus is configured to move in a secondary
(e.g., smaller amplitude) motion in addition to or instead of the
translating motion. For example, the one of the components of the
layer forming apparatus may be configured to vibrate, stutter,
oscillate, jitter, fluctuate, pulsate, and/or flutter during the
translating. In some cases, the secondary motion facilitates the
forming mechanism (e.g., material dispensing, leveling and/or
material removing) of at least one of the components. FIG. 34B
schematically depicts a (e.g., bottom) view of an example of a
layer forming apparatus (e.g., 3420) showing a material dispenser
(e.g., 3422), a leveler (e.g., 3423) and a material remover (e.g.,
3424). In some embodiments, the layer forming apparatus has an
elongated shape (e.g., greater length (e.g., 3436) than width
(e.g., 3438)). In some embodiments, the material dispenser, leveler
and material remover are integrated as a unit (e.g., one piece). In
some embodiments, two of the material dispenser, leveler and
material remover are part of a first unit and the other of the
material dispenser, leveler and material remover is part of a
second unit. For example, the material remover and the leveler may
be part of the first unit and the material dispenser can be part of
the second unit. In some embodiments, each of the material
dispenser, leveler and material remover are part of different
respective units (e.g., first, second and third pieces). The units
may be (e.g., detachably) coupled with each other. The material
dispenser can include one or more openings (e.g., 3426) where
(e.g., pre-transformed) material can travel through to the material
bed. The leveler can include one or more blades (e.g., 3428) that
may contact and planarize the material bed. The blade(s) of the
leveler can have an elongated edge. The material remover and
include one or more openings (e.g., 3430) where (e.g.,
pre-transformed) material can enter from the material bed (e.g.,
propelled by an attractive force from the material remover (e.g.,
vacuum)). In some cases, each of the one or more material dispenser
openings (e.g., 3426) and/or the one or more material remover
openings (e.g., 3430) can be elongated (e.g., slit). The one or
more material dispenser and/or material remover openings and have
any suitable shape, e.g., have any suitable cross section shape
(e.g., elliptical, round, irregular, polygonal (e.g., rectangular,
square, triangular, hexagonal)). As described herein, the layer
forming apparatus can be configured to traverse (e.g., translate)
in one (e.g., first) direction (e.g., 3432) and/or another (e.g.,
second) direction (e.g., 3434).
[0347] In some embodiments, the one or more controllers may control
the operation of the one or more components of the layer forming
mechanism. For example, the controller may turn on a component of
the layer forming mechanism (e.g., the material dispensing
mechanism), for example, when the separator (e.g., door) between
the ancillary chamber and the processing chamber is open. The one
or more controllers may control movement of one or more components
of the layer forming apparatus. For example, a first controller may
control translation of the layer forming apparatus (e.g., including
one or more of the material dispenser, leveler, and material
remover) (e.g., 3406 and/or 3407). A second controller may control
secondary movement (e.g., vibration) of one or more of the material
dispenser, leveler, and material remover. A third controller may
control functioning of one or more of the component (e.g., control
dispensing of material from the material dispenser, control
movement of the leveler (e.g., blade), and/or control the
attractive force (e.g., vacuum) of the material remover). At times,
the first controller, second controller, and the third controller
are the same controller. At times, at least two of the first
controller, second controller, and the third controller are
different controllers. The controller may control the operation of
the vibration mechanism. For example, the vibration mechanism may
be turned on when the material dispensing system may be in
operation, or when the material levelling system may be in
operation. In some embodiments, the vibration mechanism is turned
off when the material removal system may be in operation. The
control may be before, during, and/or after the three-dimensional
printing.
[0348] In some cases, the layer forming apparatus is configured to
traverse in a direction that is (e.g., substantially) different
than or (e.g., substantially) the same as a direction of a flow of
gas within the enclosure. For example, the gas flow director (also
referred to herein as a gas flow mechanism, a gas flow management
system, or a gas flow management arrangement) can be configured to
direct a flow of gas in a direction adjacent (e.g., (e.g.,
substantially) parallel) to (e.g., a top surface of) the platform.
The gas flow mechanism can direct a flow of gas from one side of
the enclosure to its opposing side of the enclosure. The flow of
gas may be (e.g., substantially) uniform (e.g., laminar). The gas
flow director can be configured to control at least one of a
trajectory, a velocity, and/or a uniformity of the flow of gas. The
gas flow director can include one or more valves that control a
velocity and/or pressure of the flow of gas within the enclosure.
The gas flow director can include the gas inlet portion, the gas
outlet portion, or any suitable combination thereof. As described
herein, the gas inlet portion can include an (e.g., elongated)
opening that imparts a (e.g., substantially) planar shape to the
flow of gas, e.g., an overall planar shape of the gas flow, which
flow can be adjacent to the target surface. The gas inlet portion
can include at least one baffle that may change a gas flow
direction within the gas inlet portion (e.g., to a third direction
different than the first and/or second directions). The gas inlet
portion can include at least one alignment structure that aligns
portions of a gas flow within the gas inlet portion (e.g., in
accordance with the direction of gas flow adjacent the target
surface and/or the platform). In some cases, the enclosure is
operatively coupled to, or comprises, the gas inlet portion and/or
the gas outlet portion. As described herein, the gas inlet portion
and/or the gas outlet portion can be fixedly coupled (e.g.,
integrally formed) with the enclosure or detachably coupled with
the enclosure. The flow management apparatus is configured to
direct the flow of gas over the platform. FIG. 35 shows a plan view
(e.g., top section view) of an example 3D printing system. The
enclosure (e.g., 3500) of the 3D printing system can be operatively
coupled to, or comprise, a processing chamber (e.g., 3502), a gas
inlet portion (e.g., 3504), a gas outlet portion (e.g., 3506),
and/or an optional ancillary chamber (e.g., 3508). The processing
chamber may be separated from the inlet portion by a (e.g., first)
separator (e.g., 3409), which can include a wall and/or opening
(e.g., 3510) that can be closeable by a gate (also referred to as a
door). The processing chamber may be separated from the ancillary
chamber by a (e.g., second) separator (e.g., 3411), which can
include a wall and/or opening (e.g., 3512) that can be closeable by
a gate (also referred to as a door). The processing chamber may be
separated from the outlet portion by a (e.g., third) separator
(e.g., 3413), which can include a wall and/or opening (e.g., 3514)
that can be closeable by a gate (also referred to as a door). The
one or more of the openings (e.g., 3510, 3512 or 3514) may be
sealably closed (e.g., gas tight seal) or may be closed in a way
that allows at least partial mixing of atmospheres of. The
processing chamber can accommodate at least a portion of the
platform (e.g., 3515) that may support the material bed and/or the
3D object during a printing operation. The processing chamber can
include one or more optical windows. The processing chamber can
include one or more recessed portions. The gas inlet portion can
include one or more inlet ports (e.g., 3516), one or more baffles
(e.g., FIG. 22, FIG. 23 (3215)), and/or one or more flow aligning
structures (e.g., FIGS. 32A-32B or 33A-33E), e.g., as described
herein. In some cases, the gas inlet portion is configured to
direct a flow of gas toward the target surface and/or the plate
(e.g., FIG. 28 or 29A-29B). The ancillary chamber can accommodate a
layer forming apparatus (e.g., 3517). The outlet portion may have
an aerodynamic shape (e.g., FIG. 30A-30D or 31) and/or can include
one or more outlet ports (e.g., 3518).
[0349] The gas flow director can direct a flow of gas (e.g., 3519)
in one or more (e.g., prescribed) directions relative to one or
more directions of travel (e.g., 3520) of the layer forming
apparatus or any of its components. In some embodiments, the layer
forming apparatus (or any of its components) traverses in a first
direction (e.g., across a portion of the processing chamber) and
the gas flows in the processing chamber in a second direction. The
first direction may be the same as the second direction. The first
direction may be different from the second direction. The first
direction may be (e.g., substantially) parallel to the second
direction. The first direction may non-parallel to second
direction. The first direction may be opposite to the second
direction. The first direction may have a direction component that
opposes the second direction. The first direction may have a
direction component that is the same as the second direction. FIG.
35 shows a direction (e.g., z direction) of travel of the layer
forming apparatus that is (e.g., substantially) non-parallel to the
direction (e.g., x direction) of the flow of gas (e.g., in
accordance with angle 3521). In some embodiments, the direction of
travel of the layer forming apparatus is (e.g., substantially)
orthogonal with respect to the direction of gas flow (e.g., angle
3521 is (e.g., about) 90 degrees). FIG. 36A shows an example of a
printing system with an enclosure 3600 having a gas inlet portion
3602, a gas outlet portion 3604, and multiple optional ancillary
chambers 3606 and 3608. The ancillary chamber(s) can each be
configured to accommodate one or more layer forming apparatuses
(e.g., 3609). The one or more layer forming apparatuses may transit
(e.g., 3610) (e.g., between two or more ancillary chambers). For
example, the one or more layer forming apparatuses can be housed in
one ancillary chamber prior to a layer forming operation, and be
housed in another ancillary chamber after the layer forming
operation (e.g., prior to and/or after a transformation operation
(e.g., using an energy beam)). In some embodiments, the system
includes one layer forming apparatus that transits among the
multiple ancillary chambers. In some embodiments, the system
includes multiple layer forming apparatuses (or components thereof)
that transit among multiple ancillary chambers. FIG. 36B shows an
example of a printing system with an enclosure 3620 having a gas
inlet portion 3622, a gas outlet portion 3624, and an optional
ancillary chamber 3626. The ancillary chamber can be configured
such that one or more layer forming apparatuses (e.g., 3629)
travels in one or more directions (e.g., 3630) that is/are at an
angle (e.g., 3632) with respect to the direction (e.g., 3634) of
the flow of gas. In some embodiments, the angle (e.g., 3632) is not
(e.g., substantially) 90 degrees (e.g., orthogonal) and/or not
(e.g., substantially) zero (e.g., parallel). FIG. 36C shows an
example of a printing system with an enclosure 3640 having a gas
inlet portion 3642 and a gas outlet portion 3644. The layer forming
apparatus (e.g., 3649) can be housed in the gas inlet portion or in
an optional ancillary chamber that is adjacent (e.g., below, above,
or lateral to) the gas inlet portion. The layer forming apparatus
can transit in one or more directions (e.g., 3646) that is/are
(e.g., substantially) parallel with respect to the direction (e.g.,
3648) of gas flow. FIG. 36D shows an example of a printing system
with an enclosure 3660 having a gas inlet portion 3662 and a gas
outlet portion 3664. The layer forming apparatus (e.g., 3669) can
be housed within the gas outlet portion or within an optional
ancillary chamber that is adjacent (e.g., below, above, or lateral
to) the gas outlet portion. The layer forming apparatus can transit
in one or more directions (e.g., 3665) that is/are (e.g.,
substantially) parallel with respect to the direction (e.g., 3668)
of gas flow.
[0350] In some cases, the flow of gas and movement (e.g.,
translation) of the layer forming apparatus are operationally
coupled. Operational coupling may be used to change (e.g., decrease
or increase) an amount of turbulence of material (e.g., of
pre-transformed material (e.g., powder) and/or debris) within
and/or around the material bed. Characteristics (e.g., shape,
velocity, uniformity, volume, and/or timing) of the flow of gas
adjacent the target surface and/or platform can be adjusted based
on movement and/or location of the layer forming apparatus. For
example, the gas flow director can be configured to direct the flow
of gas adjacent to the target surface and/or the platform when the
layer forming apparatus is or is not traversing adjacent the target
surface and/or the platform. The gas flow director can be
configured to direct the flow of gas adjacent to the target surface
and/or the platform at least partially based on an amount of debris
(e.g., as detected by one or more sensors (e.g., within the
processing chamber)). Characteristics (e.g., shape, velocity,
uniformity, volume, chemical contents, and/or timing) of the flow
of gas adjacent the target surface and/or platform can be adjusted
based on movement and/or location of the layer forming apparatus.
Movement (e.g., translation) and location of the layer forming
apparatus can be adjusted based on characteristics of the flow of
gas. For example, the flow management apparatus can direct the flow
of gas adjacent the target surface and/or platform (i) while the
layer forming apparatus is forming the layer of pre-transformed
material, (ii) while the layer forming apparatus is in the
ancillary chamber, or (iii) any combination thereof. In some cases,
the flow management apparatus can direct the flow of gas away from
the target surface and/or platform while the layer forming
apparatus forms the layer of pre-transformed material. Away from
the platform can be towards a position outside and/or inside of the
enclosure. Away from the platform can be toward a surface other
than the target surface and/or platform. In some cases, the flow
management apparatus can lower the velocity of (e.g., turn off) the
flow of gas, e.g.: while the layer forming apparatus forms the
layer of pre-transformed material, and/or while the transforming
energy beam is not operational (e.g., not transforming). As
described herein, the system can include one or more controllers to
control the layer forming apparatus and/or gas flow. FIG. 37 shows
an example of a plan view (e.g., top section view) of an example 3D
printing system. The enclosure (e.g., 3700) of the 3D printing
system can be operatively coupled to, or comprise, a processing
chamber (e.g., 3702), a gas inlet portion (e.g., 3704), a gas
outlet portion (e.g., 3706), and/or an optional ancillary chamber
(e.g., 3708). One or more pumps (e.g., 3710) can be used to
increase a pressure (velocity) of gas entering the gas inlet port
(e.g., 3712). In some cases, the system is configured to
recirculate gas from gas outlet port (e.g., 3714), through the one
or more pumps, and back through the gas inlet port. In some
embodiments, the gas recirculation is part of a (e.g.,
pre-transformed) material recirculation system as described herein.
In some embodiments, the velocity of the flow of gas (e.g., 3718)
within the enclosure and/or adjacent (e.g., over) the target
surface and/or the platform (e.g., 3720) is modified during one or
more operations of the layer forming apparatus (e.g., 3716). For
example, the flow of gas can be at a first velocity adjacent (e.g.,
over) the target surface and/or the platform during a
transformation operation (e.g., during exposure of the target
surface to an energy beam), and changed (e.g., altered, e.g.,
reduced or increased) to a second velocity during a time that the
layer forming apparatus is forming a layer on the platform. The
reduction can be to a (e.g., substantially) zero velocity. The
reduction can be a diminished flow velocity, or to lack of flow. In
some cases, the velocity change can reduce or increase a chaotic
gas flow (e.g., turbulence) within and/or around the material bed.
The second velocity can be less than the first velocity. The second
velocity can be greater than the first velocity. In some
embodiments, the change in velocity involves changing among two or
more velocities (e.g., first, second, third, fourth, or fifth
velocities). In some cases, the velocity change is accomplished by
modifying an operation of the one or more pumps (e.g., 3710). For
example, the one or more pumps can be turned off/on, and/or sped up
or down. In some cases, the velocity change is accomplished using
one or more flow diverters (e.g., 3726) within the enclosure (e.g.,
within the processing chamber). The flow diverters can be (e.g.,
modular and/or movable) baffle(s). The flow diverter(s) can include
a surface that directs the flow of gas away from the target surface
and/or the platform. In some cases, the velocity change involves
modifying an operation of one or more valves (e.g., 3722 and/or
3724). The one or more valves can constrict the flow of gas,
obstruct the flow of gas, divert the flow of gas, or any suitable
combination thereof. The valve(s) can include any suitable type of
valve(s), e.g., as described herein. In some embodiments, one or
more downstream valves (e.g., 3722) is disposed downstream of the
one or more pumps. The one or more downstream valves may divert
(e.g., 3723) all or a portion of the flow of gas (e.g., the entire
flow of gas) toward the gas outlet port. The diverted flow of gas
can flow through a gas recycling system (e.g., to one or more
filter systems). In some embodiments, one or more upstream valves
(e.g., 3724) are disposed upstream of the one or more pumps, e.g.,
to control the flow of gas to the pump(s). Changing the velocity
and/or direction of the flow of gas can include using any suitable
combination of valves, flow diverters, and/or pump adjustments. The
change may be controlled, e.g., manually and/or automatically
(e.g., using one or more controllers).
EXAMPLES
[0351] The following are illustrative and non-limiting examples of
methods of the present disclosure.
Example 1
[0352] Peak intensity reduction (PIR) measurements were made on a
3D printer as disclosed herein with and without a gas purge window
holder. The 3D printer comprises a 28 cm by 28 cm by 30 cm
container at ambient temperature, Inconel 718 powder of average
particle size 35 .mu.m was deposited in a container to form a
powder bed. A laser beam having a power setting of 500 Watts was
used, with a period of time between measurements of about 1000
msec. Table 1 below shows a comparison of PIR data calculated using
Equation 1 described herein. The data was collected after
transformation of 1, 500, 1000, 2,000, 5,000 and 10,000 layers of
Inconel 718 powder. The volume of pre-transformed material that is
transformed per layer was about 3.4 milliliters (e.g., about 3.4
liters per 1000 layers).
TABLE-US-00001 TABLE 1 Layer number PIR with purge PIR without
purge 1 0.92 0.92 500 0.92 0.75 1000 0.92 0.5 2000 0.92 0.3 5000
0.92 0.15 10000 0.92 0.1
[0353] Table 1 indicates a comparison between peak intensity of the
energy beam experienced at the target surface, as a function of the
number of layers of pre-transformed material printed (i) when there
is gas purge adjacent to the window ("PIR with purge" in Table 1),
and (ii) when there is no gas purge adjacent to the window ("PIR
without purge" in Table 1). Table 1 indicates that the PIR of a 3D
printing system devoid of gas purging of the window is reduced to
about 82% of its original peak intensity (as experienced at the
target surface) after transforming 500 layers, to about 54% of its
original peak intensity after transforming 1000 layers, to about
33% of its original peak intensity after transforming 2000 layers,
to about 16% of its original peak intensity after transforming 5000
layers, and to about 1% of its original peak intensity after
transforming 1000 layers of the 718 Inconel powder. As a
comparison, when the gas is purging the window in the 3D printing
system, a (e.g., substantially) undetectable reduction in PIR is
experienced at the target surface after forming the respective
number of layers. The experimental parameter and their respective
values are delineated in Table 2
TABLE-US-00002 TABLE 2 Parameter Value N.sub.st--Number of
measurement performed 60 N.sub.av--Number of measurement points to
average out 5 .DELTA.T.sub.st--time interval between measurements
1000 msec P.sub.st--Power setting of the laser 500 W
[0354] While preferred embodiments of the present invention have
been shown and described herein, it will be obvious to those
skilled in the art that such embodiments are provided by way of
example only. It is not intended that the invention be limited by
the specific examples provided within the specification. While the
invention has been described with reference to the afore-mentioned
specification, the descriptions and illustrations of the
embodiments herein are not meant to be construed in a limiting
sense. Numerous variations, changes, and substitutions will now
occur to those skilled in the art without departing from the
invention. Furthermore, it shall be understood that all aspects of
the invention are not limited to the specific depictions,
configurations, or relative proportions set forth herein which
depend upon a variety of conditions and variables. It should be
understood that various alternatives to the embodiments of the
invention described herein might be employed in practicing the
invention. It is therefore contemplated that the invention shall
also cover any such alternatives, modifications, variations, or
equivalents. It is intended that the following claims define the
scope of the invention and that methods and structures within the
scope of these claims and their equivalents be covered thereby.
* * * * *