Apparatuses, systems and methods for three-dimensional printing

Abstract

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

1 . A system for forming a three-dimensional object, comprising:
 a powder dispenser that dispenses a powder material to form at least a first portion of a powder bed adjacent to the powder dispenser, which powder dispenser is laterally translatable with respect to the powder bed and comprises:
 (i) a reservoir comprising the powder material, 
 (ii) a powder exit opening through which the powder material exits the reservoir to form the at least the first portion of the powder bed, 
 (iii) at least one roller operatively coupled to both the powder exit opening and the reservoir, which at least one roller facilitates flow of the powder material from the reservoir through the power exit opening to form the at least the first portion of the powder bed, wherein a complete revolution of the at least one roller facilitates a continuity of the flow of the powder material to the material bed, and 
 (iv) an obstruction that obstructs the flow of the powder material to the powder bed, which obstruction is adjacent to the at least one roller; and 
   an energy source that provides an energy beam that is directed towards the powder bed, wherein the energy beam transforms a second portion of the powder bed to form a transformed material as part of the three-dimensional object.   
     
     
         2 . The system of  claim 1 , wherein the at least one roller comprises two or more rollers. 
     
     
         3 . The system of  claim 1 , wherein the powder material comprises individual particles formed of at least one member selected from the group consisting of an elemental metal, metal alloy, ceramic, and an allotrope of elemental carbon. 
     
     
         4 . The system of  claim 1 , wherein the obstruction is separated from the at least one roller by a gap. 
     
     
         5 . The system of  claim 1 , wherein the obstruction at least partially defines the exit opening. 
     
     
         6 . The system of  claim 1 , wherein the obstruction is external to the reservoir and is separated from the powder exit opening by a gap. 
     
     
         7 . The system of  claim 1 , wherein the obstruction is planar. 
     
     
         8 . The system of  claim 1 , wherein a surface of the obstruction is rough. 
     
     
         9 . The system of  claim 1 , wherein the obstruction is slanted with respect to a direction of lateral translation of the powder dispenser. 
     
     
         10 . The system of  claim 1 , wherein the obstruction comprises a first material and a body of the powder dispenser reservoir comprises a second material, wherein the first material is harder than the second material. 
     
     
         11 . The system of  claim 1 , wherein the obstruction comprises a steel alloy or ceramic. 
     
     
         12 . The system of  claim 1 , wherein the obstruction comprises a blade. 
     
     
         13 . The system of  claim 12 , wherein the blade is rigid. 
     
     
         14 . The system of  claim 12 , wherein the first portion of the powder bed comprises the second portion of the powder bed. 
     
     
         15 . The system of  claim 1 , wherein the at least one roller retains a remainder of the powder material in the reservoir. 
     
     
         16 . The system of  claim 1 , wherein the at least one roller is impassable with respect to the powder material. 
     
     
         17 . The system of  claim 1 , wherein the power exit opening has a fundamental length scale of at most about one millimeter. 
     
     
         18 . The system of  claim 1 , wherein the at least one roller has a surface that comprises protrusions or depressions. 
     
     
         19 . A method for forming a three-dimensional object comprising:
 (a) providing a powder dispenser adjacent to a powder bed, which powder dispenser is laterally translatable with respect to the powder bed and comprises:
 (i) a reservoir comprising the powder material, 
 (ii) a powder exit opening through which the powder material exits the reservoir to form the at least the first portion of the powder bed, 
 (iii) at least one roller operatively coupled to both the powder exit opening and the reservoir, which at least one roller facilitates flow of the powder material from the reservoir to the power exit opening to form the at least the first portion of the powder bed, wherein a complete revolution of the at least one roller facilitates a continuity of the flow of the powder material to the material bed, 
 (iv) an obstruction that obstructs the flow of the powder material to the powder bed, which obstruction is adjacent to the at least one roller; 
   (b) dispensing the powder material from the powder dispenser to form at least a first portion of the powder bed adjacent to the powder dispenser; and   (c) directing an energy beam from an energy source to the powder bed to transform at least a second portion of the powder bed to a transformed material as part of the three-dimensional object.   
     
     
         20 . The method of  claim 19 , wherein the obstruction restricts an amount of the powder material that exits the powder dispenser. 
     
     
         21 . The method of  claim 19 , wherein the obstruction disperses the powder material that exits the powder dispenser. 
     
     
         22 . The method of  claim 19 , wherein the first portion of the powder bed comprises the second portion of the powder bed. 
     
     
         23 . The method of  claim 19 , wherein the obstruction affects an amount of the powder material that exits the powder dispenser. 
     
     
         24 . The method of  claim 19 , wherein the obstruction comprises a rough surface. 
     
     
         25 . The method of  claim 19 , wherein the rough surface contacts the powder material that exits the powder dispenser. 
     
     
         26 . The method of  claim 19 , further comprising controlling a spacing of a gap between the powder dispenser and an exposed surface of the powder bed. 
     
     
         27 . The method of  claim 19 , wherein (b) comprises laterally translating the powder dispenser with respect to the powder bed at a controlled velocity. 
     
     
         28 . The method of  claim 19 , further comprising controlling the obstruction. 
     
     
         29 . The method of  claim 28 , wherein controlling the obstruction comprises regulating a position of the obstruction. 
     
     
         30 . The method of  claim 28 , wherein controlling the obstruction comprises controlling an angle of the obstruction.