Skillful three-dimensional printing

Abstract

The present disclosure various apparatuses, and systems for 3D printing. The present disclosure provides three-dimensional (3D) printing methods, apparatuses, software and systems for a step and repeat energy irradiation process; controlling material characteristics and/or deformation of the 3D object; reducing deformation in a printed 3D object; and planarizing a material bed.

What is claimed is: 
     
         1 . A method for printing a three-dimensional object, comprising:
 (a) providing a material bed comprising pre-transformed material that comprises an exposed surface;   (b) planarizing the exposed surface by directing an excess of the pre-transformed material from the exposed surface disposed above a plane into an internal compartment of a material remover through at least one flexible channel, to form a planarized exposed surface; and   (c) using a transforming agent to transform the pre-transformed material in at least a portion of the planarized exposed surface to a transformed material, wherein the transformed material is at least a fraction of the three-dimensional object.   
     
     
         2 . The method of  claim 1 , wherein the planarizing is in an absence of contact between the material remover and the exposed surface of the material bed. 
     
     
         3 . The method of  claim 1 , wherein the pre-transformed material is directed using an electrostatic force, a magnetic force, a gas flow, or any combination thereof. 
     
     
         4 . The method of  claim 3 , wherein the gas flow comprises use of vacuum or compressed gas. 
     
     
         5 . The method of  claim 1 , further comprising laterally translating the material remover relative to the exposed surface. 
     
     
         6 . The method of  claim 5 , further comprising altering a location of the at least one flexible channel during translation of the material remover. 
     
     
         7 . The method of  claim 5 , wherein the material remover comprises a chamber that is operatively coupled to the at least one flexible channel through an at least one opening, wherein the method comprises altering a position of the at least one opening during translation of the material remover. 
     
     
         8 . The method of  claim 7 , wherein the at least one opening is a plurality of openings. 
     
     
         9 . The method of  claim 7 , wherein the at least one flexible channel is a plurality of channels. 
     
     
         10 . The method of  claim 1 , wherein the pre-transformed material is formed of at least one member selected from the group consisting of an elemental metal, a metal alloy, a ceramic, and an allotrope of elemental carbon. 
     
     
         11 . The method of  claim 1 , wherein the pre-transformed material in at least the portion of the planarized exposed surface is transformed to the transformed material while fusing individual particles of the material bed. 
     
     
         12 . The method of  claim 1 , wherein the pre-transformed material is accumulated in the internal compartment at least in part by separating the pre-transformed material from a gas flow that is generated upon directing the pre-transformed material from the exposed surface into the internal compartment of the material remover. 
     
     
         13 . The method of  claim 12 , wherein the separating is cyclonically separating. 
     
     
         14 . The method of  claim 1 , wherein the pre-transformed material comprises at least one member selected from the group consisting of an elemental metal, a metal alloy, a ceramic, and an allotrope of elemental carbon. 
     
     
         15 . The method of  claim 1 , wherein the pre-transformed material comprises at least one member selected from the group consisting of a polymer, and a resin. 
     
     
         16 . The method of  claim 1 , wherein the pre-transformed material comprises a particulate material. 
     
     
         17 . The method of  claim 1 , wherein the at least one flexible channel is operatively coupled to a force source to facilitate direction of the excess of the pre-transformed material from the exposed surface. 
     
     
         18 . The method of  claim 1 , wherein the at least one flexible channel is a plurality of channels. 
     
     
         19 . The method of  claim 1 , wherein the at least one flexible channel comprises at a tube or a hose. 
     
     
         20 . A method for printing a three-dimensional object, comprising:
 (a) controlling planarization of an exposed surface of a material bed by directing removal of an excess of a pre-transformed material from the exposed surface disposed above a plane into an internal compartment of a material remover through at least one flexible channel, to form a planarized exposed surface; and   (b) using a transforming agent to transform the pre-transformed material in at least a portion of the planarized exposed surface to a transformed material, wherein the transformed material is at least a fraction of the three-dimensional object.   
     
     
         21 . The method of  claim 20 , wherein the planarization is in an absence of contact between the material remover and the exposed surface of the material bed. 
     
     
         22 . The method of  claim 20 , wherein the pre-transformed material is directed using an electrostatic force, a magnetic force, a gas flow, or any combination thereof. 
     
     
         23 . The method of  claim 22 , wherein the gas flow comprises use of vacuum or compressed gas. 
     
     
         24 . The method of  claim 20 , wherein controlling planarization comprises directing lateral translation of the material remover relative to the exposed surface. 
     
     
         25 . The method of  claim 24 , wherein controlling planarization comprises controlling alteration of a location of the at least one flexible channel during translation of the material remover. 
     
     
         26 . The method of  claim 20 , wherein the pre-transformed material comprises at least one member selected from the group consisting of an elemental metal, a metal alloy, a ceramic, and an allotrope of elemental carbon. 
     
     
         27 . The method of  claim 20 , wherein the pre-transformed material comprises at least one member selected from the group consisting of a polymer and a resin. 
     
     
         28 . The method of  claim 20 , wherein the pre-transformed material comprises a particulate material. 
     
     
         29 . The method of  claim 20 , wherein the at least one flexible channel is operatively coupled to a force source to facilitate directing the excess of the pre-transformed material from the exposed surface. 
     
     
         30 . The method of  claim 29 , wherein controlling planarization comprises controlling the force source to facilitate directing the excess of the pre-transformed material from the exposed surface. 
     
     
         31 . The method of  claim 30 , wherein controlling the force source comprises controlling an amount of a force exerted by the force source. 
     
     
         32 . The method of  claim 20 , wherein controlling planarization comprises controlling an amount of the excess of a pre-transformed material removed from the exposed surface. 
     
     
         33 . The method of  claim 20 , wherein controlling planarization comprises a feedback control scheme. 
     
     
         34 . The method of  claim 20 , wherein controlling planarization comprises metrologically sensing a deviation in the exposed surface. 
     
     
         35 . The method of  claim 34 , wherein metrologically sensing the deviation comprises height sensing. 
     
     
         36 . The method of  claim 34 , wherein metrologically sensing the deviation comprises optically sensing.