SKILLFUL THREE-DIMENSIONAL PRINTING
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.
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.