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 . (canceled) 
     
     
         2 . A method for printing a complex three-dimensional object, comprising: printing the complex three-dimensional object layer-by-layer adjacent to a platform, which complex three-dimensional object comprises at least one layer of hardened material that has an average layering plane; wherein during printing, an acute angle between a straight line on a surface of the complex three-dimensional object and a direction normal to the average layering plane is from about 55 degrees to about 90 degrees, which surface (i) faces the platform and (ii) has an arithmetic average of the roughness profile value (Ra) of at most 40 micrometers. 
     
     
         3 . The method of  claim 1 , wherein the arithmetic average of the roughness profile value (Ra) of at most 40 micrometers is in the absence of further processing of the complex three-dimensional object. 
     
     
         4 . The method of  claim 2 , wherein the arithmetic average of the roughness profile value (Ra) of at most 40 micrometers is in the absence of further processing of the complex three-dimensional object by trimming. 
     
     
         5 . The method of  claim 4 , wherein the trimming comprising cutting, polishing, or blasting. 
     
     
         6 . The method of  claim 2 , wherein printing the complex three-dimensional object is performed without iterative printing. 
     
     
         7 . The method of  claim 2 , wherein the fundamental length scale of the complex three-dimensional object is at least 120 micrometers. 
     
     
         8 . The method of  claim 2 , wherein the complex three-dimensional object comprises a material that includes at least one member selected from the group consisting of a metal, metal alloy, ceramic, and elemental carbon. 
     
     
         9 . The method of  claim 2 , wherein the complex three-dimensional object comprises a plurality of layers, wherein a given layer of the plurality of layers of the complex three-dimensional object has a radius of curvature of at least 5 centimeters. 
     
     
         10 . The method of  claim 2 , wherein the complex three-dimensional object comprises a plurality of layers, wherein a given layer of the plurality of layers of the complex three-dimensional object has a radius of curvature of at least 50 centimeters. 
     
     
         11 . The method of  claim 2 , wherein the printing is performed within at most about seven (7) days. 
     
     
         12 . The method of  claim 2 , wherein the complex three-dimensional object comprises a cavity. 
     
     
         13 . The method of  claim 2 , wherein printing the complex three-dimensional object layer-by-layer comprises use of powder-based three-dimensional printing. 
     
     
         14 . The method of  claim 13 , wherein the powder-based three-dimensional printing comprises using a powder bed that is supported by the platform. 
     
     
         15 . The method of  claim 14 , wherein the powder-based three-dimensional printing comprises fusing a portion of powder material of the powder bed to print the complex three-dimensional object. 
     
     
         16 . The method of  claim 15 , wherein fusing comprises melting, sintering, or bonding. 
     
     
         17 . The method of  claim 16 , wherein melting comprises entirely transforming the powder material to a liquid state. 
     
     
         18 . The method of  claim 2 , wherein the complex three-dimensional object is printed from a printing material, and wherein printing the complex three-dimensional object layer-by-layer comprises irradiating the printing material with an energy beam. 
     
     
         19 . A method for printing a complex three-dimensional object, comprising:
 printing the complex three-dimensional object layer-by-layer according to a model of the complex three-dimensional object, wherein the complex three-dimensional object is printed above a platform, which complex three-dimensional object deviates from the model of the complex three-dimensional object by at most (i) about 100 micrometers and (ii) a fundamental length scale of the complex three-dimensional object divided by 2500, and wherein the complex three-dimensional object comprises at least one layer of hardened material, wherein the complex three-dimensional object comprises a surface that faces the platform, which surface has an arithmetic average of the roughness profile (Ra) of at most 40 micrometers.   
     
     
         20 . The method of  claim 19 , wherein the complex three-dimensional object comprises a cavity. 
     
     
         21 . The method of  claim 19 , wherein printing the complex three-dimensional object is without iterative printing. 
     
     
         22 . The method of  claim 19 , wherein the arithmetic average of the roughness profile value (Ra) of at most 40 micrometers is in the absence of further processing of the complex three-dimensional object. 
     
     
         23 . The method of  claim 22 , wherein the arithmetic average of the roughness profile value (Ra) of at most 40 micrometers is in the absence of further processing of the complex three-dimensional object by trimming. 
     
     
         24 . The method of  claim 23 , wherein the trimming comprising cutting, polishing, or blasting. 
     
     
         25 . The method of  claim 19 , wherein the complex three-dimensional object comprises a plurality of layers, wherein a given layer of the plurality of layers of the complex three-dimensional object has a radius of curvature of at least 5 centimeters. 
     
     
         26 . The method of  claim 19 , wherein the complex three-dimensional object comprises a plurality of layers, wherein a given layer of the plurality of layers of the complex three-dimensional object has a radius of curvature of at least 50 centimeters.