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.

What is claimed is: 
     
         1 . A device for generating a planar layer of powder material, the device comprising:
 a dispenser configured to (A) contain powder material, (B) dispense at least a portion of the powder material through an opening of the dispenser (I) to generate a powder bed and (II) to extend the powder bed to generate an extended powder bed, and (C) dispense the at least the portion of the powder material on a first exposed surface of the powder bed that includes at least one three-dimensional object that protrudes from the first exposed surface of the extended powder bed; and   a remover configured to remove powder material from first exposed surface of the extended powder bed to generate a second exposed surface of a remainder of the extended powder bed at least in part by being configured to operatively couple to an attractive force source to operatively couple the attractive force with the extended powder bed, the attractive force attracting powder material from the extended powder bed to form the planar layer having the second exposes surface as part of the remainder of the extended powder bed, the second exposed surface being planar.   
     
     
         2 . The device of  claim 1 , wherein the device is configured to dispense the planar layer of powder material while maintaining a gap with the extended powder bed such that the device dispenses the planar layer of powder material without contacting the extended powder bed. 
     
     
         3 . The device of  claim 1 , wherein a vertical position of the dispenser, and/or remover is adjustable. 
     
     
         4 . The device of  claim 1 , wherein the dispenser comprises a slanted plane (a) that is operatively coupled to the opening or (b) that is at least a portion of the opening; and
 wherein during operation of the dispenser, the dispenser is configured to facilitate flow of the powder material through the opening and on the slanted plane.   
     
     
         5 . The device of  claim 1 , wherein the attractive force comprises vacuum. 
     
     
         6 . The device of  claim 1 , wherein the attractive force comprises a magnetic force, an electric force, or an electrostatic force. 
     
     
         7 . The device of  claim 1 , wherein the dispenser is operatively coupled to, or comprises, a shaker configured to shake the at least the portion of the powder material for dispensing from the opening of the dispenser, the shaker (i) being operatively coupled to the dispenser or (ii) being part of the dispenser. 
     
     
         8 . The device of  claim 7 , wherein the dispenser comprises an opening configured to facilitate flow of the powder material from the dispenser towards the powder bed, and wherein the shaker is configured to shake at least a portion of the opening through which the powder material exits the dispenser. 
     
     
         9 . The device of  claim 7 , wherein the shaker comprises an ultrasonic transducer, a piezoelectric device, a rotating motor, or any combination thereof. 
     
     
         10 . The device of  claim 1 , wherein the device is configured to dispense the planar layer of powder having a material comprising elemental metal, metal alloy, ceramic, or an allotrope of elemental carbon. 
     
     
         11 . The device of  claim 1 , wherein the device is configured to dispense the planar layer that has a deviation from planarity of at most about 30 micrometers. 
     
     
         12 . A system for generating a planar layer of powder material, the system comprising: the device of  claim 1 ; and an energy beam configured to irradiate the planar layer to print at least one three-dimensional object at least in part by using the remainder of the extended powder bed using three-dimensional printing. 
     
     
         13 . The system of  claim 12 , wherein the system comprises an enclosure in which the at least one three-dimensional object is generated in an atmosphere comprising a positive pressure above an ambient pressure external to the enclosure. 
     
     
         14 . The system of  claim 12 , wherein the system comprises an enclosure in which the at least one three-dimensional object is generated in an atmosphere that comprises oxygen at a level of at most about 10,000 ppm, and water at a level of at most about 1,000 ppm. 
     
     
         15 . An apparatus for generating a planar layer of powder material, the apparatus comprising: a control system configured to (i) operatively couple to the device of  claim 1 ; and
 (ii) direct the device to generate the planar layer of powder material.   
     
     
         16 . The apparatus of  claim 15 , wherein the control system is configured to (i) operatively couple to an energy source, and (ii) direct the energy source to generate an energy beam to print the at least one three-dimensional object at least in part by using the remainder of the powder bed. 
     
     
         17 . A non-transitory computer readable program instructions that, when executed by one or more processors operatively coupled to the device of  claim 1 , implement one or more operations comprising directing the device to generate the planar layer of powder material. 
     
     
         18 . The non-transitory computer readable program instructions of  claim 17 , wherein the one or more processors are operatively coupled to a scanner, and wherein the operations comprise directing the scanner to translate an energy beam along the second exposes surface to print the at least one three-dimensional object at least in part by using the remainder of the extended powder bed. 
     
     
         19 . A method for generating a planar layer of powder material, the method comprising:
 providing the device of  claim 1 ; and using the device to dispense the planar layer.   
     
     
         20 . The method of  claim 19 , wherein the powder material comprises elemental metal, metal alloy, an allotrope of elemental carbon, or a ceramic. 
     
     
         21 . The method of  claim 19 , further comprising printing at least one three-dimensional object at least in part by using the remainder of the extended powder bed. 
     
     
         22 . The method of  claim 21 , wherein the at least one three-dimensional object (i) comprises a cavity devoid of auxiliary support and/or (ii) is suspended in the remainder of the powder bed devoid of auxiliary supports connected to a base supporting the remainder of the powder bed.