Apparatuses and methods for 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 . An apparatus for printing a three-dimensional object, comprising at least one controller that is operatively coupled to a first energy source and to a second energy source, which at least one controller comprises at least one electrical circuitry configured to direct during printing:
 (a) the first energy source to irradiate a first energy beam to transform a pre-transformed material into a transformed material according to a first transformation scheme to form a plurality of layers of transformed material as part of the three-dimensional object; and   (b) the second energy source to irradiate a second enemy beam to transform at least a portion of two or more layers of the plurality of layers of transformed material according to a second transformation scheme.   
     
     
         2 . The apparatus of  claim 1 , wherein the second transformation scheme results in alteration of a porosity of the at least the portion of two or more layers of the plurality of layers of transformed material. 
     
     
         3 . The apparatus of  claim 1 , wherein the at least one controller is configured to direct printing the three-dimensional object having different microstructures at different requested locations of the three-dimensional object. 
     
     
         4 . The apparatus of  claim 1 , wherein the at least one controller is configured to direct printing the three-dimensional object having different porosities at different requested locations of the three-dimensional object. 
     
     
         5 . The apparatus of  claim 1 , wherein the first transformation scheme comprises melting the pre-transformed material to form a molten material, and wherein the at least controller is configured to direct (i) the first energy source and/or (ii) the second energy source to vary a cooling rate of molten material. 
     
     
         6 . The apparatus of  claim 1 , wherein the first transformation scheme results in forming one or more melt pools, wherein the at least one controller is configured to direct (i) the energy source and/or (ii) the second energy source to vary a cooling rate of the one or more melt pools. 
     
     
         7 . The apparatus of  claim 1 , wherein after (b), the at least one controller is configured to direct (i) the first energy source to irradiate the first energy beam, and/or (ii) the second energy source to irradiate the second energy beam, to transform a pre-transformed material into a transformed material to form a layer of transformed material on the plurality of layers of transformed material. 
     
     
         8 . The apparatus of  claim 1 , wherein the first energy source and the second energy source are the same energy beam. 
     
     
         9 . The apparatus of  claim 1 , wherein the second transformation scheme comprises annealing. 
     
     
         10 . The apparatus of  claim 1 , wherein the second transformation scheme comprises altering a microstructure of at least a portion of two or more layers of the plurality of layers of transformed material. 
     
     
         11 . The apparatus of  claim 1 , wherein the at least size controller is operatively coupled to a cyclonic separator and is configured to direct the cyclonic separator to separate any gas from the pre-transformed material during printing. 
     
     
         12 . The apparatus of  claim 1 , wherein the at least one controller is operatively coupled to a first optical element, and wherein the at least one controller is configured to direct the first optical element to translate the first energy beam according to the first transformation scheme; and wherein the at least one controller is operatively coupled to a second optical element, and wherein the at least one controller is configured to direct the second optical element to translate the second energy beam according to the second transformation scheme. 
     
     
         13 . The apparatus of  claim 12 , wherein the first optical element and the second optical element are the same optical element. 
     
     
         14 . A method for printing a three-dimensional object, comprising:
 (a) during printing, using a first transformation type to transform a pre-transformed material into a transformed material to form a plurality of layers of transformed material as part of the three-dimensional object; and.   (b) during printing, using a second transformation type to transform at least a portion of two or more layers of the plurality of layers of transformed material.   
     
     
         15 . The method of  claim 14 , wherein usage of the second transformation type results in the three-dimensional object having different porosities in different requested locations of the three-dimensional object. 
     
     
         16 . The method of  claim 14 , wherein the second transformation type comprises altering a porosity of the at least the portion of two or more layers of the plurality of layers of transformed material. 
     
     
         17 . The method of  claim 16 , wherein alteration of the porosity results in the three-dimensional object having different porosities in different requested locations of the three-dimensional object. 
     
     
         18 . The method of  claim 14 , wherein usage of the second transformation type results in the three-dimensional object having varied microstructure in requested locations of the three-dimensional object. 
     
     
         19 . The method of  claim 14 , wherein the second transformation type comprises altering a microstructure of the at least the portion of two or more layers of the plurality of layers of transformed material. 
     
     
         20 . The method of  claim 19 , wherein alteration of the microstructure results in the three-dimensional object having varied microstructure in requested locations of the three-dimensional object. 
     
     
         21 . The method of  claim 14 , wherein the first transformation type comprises forming one or more melt pools, wherein controlling comprises varying a cooling rate of the one or more melt pools. 
     
     
         22 . The method of  claim 14 , wherein the first transformation type comprises melting the pre-transformed material to form a molten material, and wherein controlling comprises varying a cooling rate of molten material. 
     
     
         23 . The method of  claim 14 , wherein the method further comprises after (b), using, the first transformation type to transform a pre-transformed material into a transformed material to form a layer of transformed material on the plurality of layers of transformed material. 
     
     
         24 . The method of  claim 14 , wherein the second transformation type comprises altering a porosity of at least a portion of two or more layers of the plurality of layers of transformed material. 
     
     
         25 . The method of  claim 14 , wherein the second transformation type comprises annealing. 
     
     
         26 . The method of  claim 25 , wherein the annealing comprises altering a porosity of the three-dimensional object.