EP4294591A1 - Gasstrom beim dreidimensionalen drucken - Google Patents

Gasstrom beim dreidimensionalen drucken

Info

Publication number
EP4294591A1
EP4294591A1 EP22756811.0A EP22756811A EP4294591A1 EP 4294591 A1 EP4294591 A1 EP 4294591A1 EP 22756811 A EP22756811 A EP 22756811A EP 4294591 A1 EP4294591 A1 EP 4294591A1
Authority
EP
European Patent Office
Prior art keywords
gas
flow
gas flow
enclosure
channel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22756811.0A
Other languages
English (en)
French (fr)
Inventor
Joseph Andrew TRALONGO
Robin Tuluie
Rebel-Angel ERATT-CAMP
Nicolas HAAG
Benyamin Buller
Erel Milshtein
Zachary Ryan MURPHREE
Claus Wemer ENDRUHN
Anastasios Michail LAPPAS
Thomas Brezoczky
Alexander Brudny
Sergey Borisovich KOREPANOV
Kenji Terata BOWERS
Robert Michael MARTINSON
Yacov Elgar
Charudatta Mukundrao CHOUDHARI
Richard Joseph ROMANO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Velo3D Inc
Original Assignee
Velo3D Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Velo3D Inc filed Critical Velo3D Inc
Priority claimed from PCT/US2022/016550 external-priority patent/WO2022177952A1/en
Publication of EP4294591A1 publication Critical patent/EP4294591A1/de
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • B22F10/322—Process control of the atmosphere, e.g. composition or pressure in a building chamber of the gas flow, e.g. rate or direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/38—Housings, e.g. machine housings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/70—Gas flow means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

Definitions

  • Three-dimensional (3D) printing is a process for making a three-dimensional object of any shape from a design.
  • the design may be in the form of a data source such as an electronic data source, or may be in the form of a hard copy.
  • the hard copy may be a two-dimensional representation of a 3D object.
  • the data source may be an electronic 3D model.
  • 3D printing may be accomplished through an additive process in which successive layers of material are laid down one on top of another. This process may be controlled (e.g., computer controlled, manually controlled, or both).
  • a 3D printer can be an industrial robot.
  • 3D printing can generate custom parts.
  • materials can be used in a 3D printing process including elemental metal, metal alloy, ceramic, elemental carbon, or polymeric material.
  • 3D printing processes e.g., additive manufacturing
  • a first layer of hardened material is formed (e.g., by welding powder), and thereafter successive layers of hardened material are added one by one, wherein each new layer of hardened material is added on a pre-formed layer of hardened material, until the entire designed three- dimensional structure (3D object) is layer-wise materialized.
  • 3D models may be created with a computer aided design package, via 3D scanner, or manually.
  • the manual modeling process of preparing geometric data for 3D computer graphics may be similar to plastic arts, such as sculpting or animating.
  • 3D scanning is a process of analyzing and collecting digital data on the shape and appearance of a real object (e.g., real-life object). Based on this data, 3D models of the scanned object can be produced.
  • a number of 3D printing processes are currently available. They may differ in the manner layers are deposited to create the materialized 3D structure (e.g., hardened 3D structure). They may vary in the material or materials that are used to materialize the designed 3D object. Some methods melt, sinter, or soften material to produce the layers that form the 3D object. Examples for 3D printing methods include selective laser melting (SLM), selective laser sintering (SLS), direct metal laser sintering (DMLS) or fused deposition modeling (FDM). Other methods cure liquid materials using different technologies such as stereo lithography (SLA). In the method of laminated object manufacturing (LOM), thin layers (made inter alia of paper, polymer, or metal) are cut to shape and joined together.
  • SLM selective laser melting
  • SLS selective laser sintering
  • DMLS direct metal laser sintering
  • FDM fused deposition modeling
  • SLA stereo lithography
  • LOM laminated object manufacturing
  • thin layers made inter alia of paper, polymer, or metal
  • the energy beam may be projected on a material bed to transform a portion of the pre-transformed material to form the 3D object.
  • debris e.g., metal vapor, molten metal, or plasma
  • the debris may be generated in the enclosure (e.g., above the material bed).
  • the debris may float in the enclosure atmosphere.
  • the floating debris may alter at least one characteristic of the energy beam (e.g., its power per unit area) during its passage through the enclosure towards material bed.
  • the debris may alter (e.g., damage) to various components of the 3D printing system (e.g., optical window).
  • Some existing 3D printers establish cross flow of gas to reduce the debris in the enclosure atmosphere.
  • the material forms may compromise (e.g., fine) powder or soot.
  • Some of the gas-borne material may be susceptible to reaction with a reactive agent (e.g., an oxidizing agent).
  • a reactive agent e.g., an oxidizing agent.
  • Some of the gas-borne material may violently react (e.g., when coming into contact with the reactive agent).
  • it may be requested (e.g., may be desirable) to provide low leakage of the reactive agent (e.g., oxygen in the ambient atmosphere) into one or more segments of the 3D printer.
  • the interior of one or more segments of the 3D printer may be desirable to isolate the interior of one or more segments of the 3D printer from a harmful (e.g., violently reactive) level of the reactive agent (e.g., that is present in the atmosphere external to the one or more segments of the 3D printer).
  • a harmful (e.g., violently reactive) level of the reactive agent e.g., that is present in the atmosphere external to the one or more segments of the 3D printer.
  • it may be desirable to preserve a non-reactive (e.g., inert) atmosphere in at least one segment of the 3D printer e.g., before, during and/or after the 3D printing).
  • gas-borne material may be collected within a filtering mechanism.
  • the gas- borne material may violently react (e.g., ignite, flame and/or combust), when exposed to an atmosphere comprising the reactive agent (e.g., an ambient atmosphere comprising oxygen).
  • an atmosphere comprising the reactive agent e.g., an ambient atmosphere comprising oxygen
  • a filter mechanism that maintains an inert interior atmosphere around the filter, at least during the filtering operation and/or disassembling of the filter from the filtering mechanism.
  • a window holder facilitating shielding of an optical window such that the optical window will require minimal maintenance.
  • the maintenance is in a frequency of no more than every month, every half a year, or every year, e.g., with the 3D printing system working at a capacity of at least about 60%, 70%, 80%, or 90%.
  • the window holder may be a device facilitating gas flow, e.g., in a direction away from the optical window.
  • the window holder may be a nozzle (e.g., nozzle configured for gas flow).
  • a device for gas flow comprises: a holder of an optical window disposed in an enclosure in which a process is taking place, which process generates debris, which holder is configured to facilitate gas flow that shields the window such that maintenance of the window is required at most about every 30 days, with the process occurring at least at a 60 or 70 percent capacity.
  • the process comprises a three-dimensional printing process that prints one or more three-dimensional objects in a printing cycle.
  • the process comprises transforming a material comprising an elemental metal, a ceramic, an allotrope of elemental metal, or a metal alloy.
  • the optical window is configured to transmit an energy beam comprising a laser beam.
  • a method for gas flow comprises: flowing gas through a holder of an optical window disposed in an enclosure in which a process is taking place, which process generates debris, which holder is configured to facilitate the gas flow such that the gas flow shields the window resulting in a maintenance of the window at most about every 30 days, with the process occurring at least at a 60 or 70 percent capacity.
  • an apparatus for gas flow comprises: at least one controller configured to: (a) operatively couple to the device and/or to a gas flow system; and (b) control, or direct control of, the gas flow by using the devices above.
  • an apparatus for gas flow comprising at least one controller configured to: (a) operatively couple to a gas conveyance system; and (b) direct the gas conveyance system to flowing gas through a holder of an optical window disposed in an enclosure in which a process is taking place, which process generates debris, which holder is configured to facilitate the gas flow such that the gas flow shields the window resulting in a maintenance of the window at most about every 30 days, with the process occurring at least at a 60 or 70 percent capacity.
  • the at least one controller is configured to control the process.
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors operatively coupled to a gas flow system; cause the one or more processors to execute one or more operations comprising controlling, or directing control of, the gas flow by using the devices above.
  • a device for gas flow the device comparing: a nozzle having an outer side surface and an opposing inner side surface surrounding an inner cavity of the nozzle, the nozzle being configured to facilitate gas flow through the outer side surface into the inner cavity of the nozzle, and out of an open end of the inner cavity of the nozzle, the nozzle comprising: (i) holes surrounding the inner cavity configured to facilitate the gas flow into the cavity, (ii) stationary vanes configured to direct the gas to flow into the cavity and to the open end of the cavity, (iii) partitions configured to facilitate directing the gas into the cavity and to the open end of the cavity, (iv) the outer side surface having a first shape of a first side surface of a first truncated cone, and/or (v) an inner side surface having a second shape of a second side surface of a second truncated cone, which inner side surface is of the inner cavity.
  • the nozzle is configured to minimize turbulence and/or back flow of gas towards an end of the cavity opposing the open end.
  • the outer side surface and the inner side surface are disposed at opposing sides of a wall of the nozzle.
  • the holes penetrate the wall.
  • the holes extend through a width of the wall as they extend from the outer side surface, through a body of the wall, and out of the inner side surface of the wall, to form open ended holes.
  • the outer side surface is disposed at a first plane different than a second plane enclosed by the open end. In some embodiments, the outer side surface is disposed at a first plane comprising a curvature.
  • the device is configured to flow gas comprising a recycled and/or filtered gas. In some embodiments, the device is configured to flow gas comprising a gas flowing in a closed gas flow system. In some embodiments, the device includes a material comprising elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon. In some embodiments, the device includes components comprising the stationary vanes and the partitions, and wherein at least one component of the components includes a material comprising elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon. In some embodiments, the outer side surface is a closed surface of a first three-dimensional geometric shape, wherein the inner side surface is a closed surface of a second three-dimensional geometric shape.
  • the first truncated cone and the second truncated cone expand on the same end of the nozzle.
  • the first truncated cone has the same slant angle as the second truncated cone.
  • the first truncated cone has a different slant angle than the second truncated cone.
  • the partitions are disposed along planes symmetrically arranged along the inner side surface of the nozzle coaxially with the inner side surface.
  • the stationary vanes are disposed coaxially to the inner side surface.
  • the outer surface comprises holes arranged in evenly spaced rows that are coaxial with the inner side surface.
  • the number of rows are at least 2, 3, 6, 9, 12, or 15 rows.
  • a cross section of the nozzle is a circle, wherein the holes are evenly distributed across a circumference of the circle, and wherein two immediately adjacent holes are disposed along an arch having an angle of at most about 0.5, 1 , 1.5, 2, 2.5, or 3 degrees, wherein the two immediately adjacent holes are devoid of an intervening hole.
  • a cross section of the nozzle is a circle, wherein the holes are evenly distributed across a circumference of the circle, wherein two immediately adjacent holes are disposed along an arch, wherein the two immediately adjacent holes are devoid of an intervening hole, and wherein a hole of the two immediately adjacent holes has a fundamental length scale that is at most about 5, 10, 20, 25, 30, 40, or 50 percent of a length of the arch.
  • the nozzle has a circular cross section having a central axis normal to the circular cross section, the outer side surface is a closed surface having the central axis, and the inner side surface is a closed surface having the central axis.
  • the open end of the cavity is along the central axis.
  • the stationary vanes are configured to direct the gas to flow into the cavity, to the open end of the cavity, and along the central axis. In some embodiments, the stationary vanes are configured to direct the gas to flow along the central axis with minimal turbulence and/or back flow towards an end of the cavity opposing the open end. In some embodiments, the partitions are configured to at least in part direct the gas into the cavity and to the open end of the cavity. In some embodiments, the partitions are configured to structurally support the stationary vanes. In some embodiments, the partitions are configured to be disposed along the central axis.
  • the stationary vanes comprise partitions disposed between every two of the stationary vanes along the nozzle inner surface, the two of the stationary vanes are immediately adjacent to each other without an intervening stationary vane, and wherein the partitions are disposed along the plane.
  • a first partition is separated from a second partition by a gap, the first partition and the second partition are disposed along a stationary vane of the stationary vanes, the first partition and the second partition are of the partitions.
  • the partitions are disposed along planes that are evenly separated along the inner side surface of the nozzle.
  • the partitions are disposed along planes symmetrically arranged along the inner side surface of the nozzle.
  • the stationary vanes are arranged along the inner surface from the open end of the nozzle towards its opposing end. In some embodiments, the stationary vanes are sequentially arranged along the inner surface. In some embodiments, the stationary vanes are evenly spaced along the inner surface. In some embodiments, the stationary vanes are unevenly spaced along the inner surface. In some embodiments, each stationary vane of the stationary vanes has an exposed end and a connected end opposing the exposed end, wherein the connected ends of the stationary vanes are disposed parallel to each other. In some embodiments, each stationary vane of the stationary vanes has an exposed end that is tapered and/or has a curved tip.
  • a radius of curvature of a vertical cross section of the stationary vanes increases linearly as a stationary vane is positioned further away from the open end of the nozzle. In some embodiments, a curvature of a vertical cross section of the stationary vanes increases according to a function as a stationary vane is positioned closer to the open end of the nozzle. In some embodiments, a curvature of a vertical cross section of the stationary vanes increases linearly as a stationary vane is positioned closer to the open end of the nozzle. In some embodiments, a curvature of a vertical cross section of a stationary vane of the stationary vanes is directed towards the open end of the nozzle.
  • At least one of the stationary vane is curved in a direction towards the open end of the nozzle. In some embodiments, at least one of the stationary vane is not curved. In some embodiments, at least one of the stationary vane is planar. In some embodiments, a first stationary vane closest to the open end is shorter than a second stationary vane farthest from the open end, wherein the first stationary vane and the second stationary vane are of the stationary vanes. In some embodiments, shorter is by at most about 5, 8, 10, 12, 15, or 20 percent.
  • the vanes are successively angled or curved with respect to a planar end of the nozzle opposing the open end, wherein the planar end of the nozzle is planar with respect to a plane, wherein a vertical cross section of a stationary vane of the stationary vanes has an exposed end and a connected end, and wherein an angle is formed between (i) a line drawn from the exposed end to the connected and (ii) the plane, or a plane parallel to the plane, of the planar end of the nozzle opposing the open end, and wherein the angle is at most about 5, 10, 15, 20, 25, 30, or 40 degrees.
  • a second stationary vane generates an angle that is greater by at least about 2, 3, 4, or 5 degrees as compared to a first stationary vane disposed immediately before the second stationary vane with respect to the open end, which angle is formed between (i) a line drawn from an exposed end of the second stationary vane to a connected of the second stationary vane and (ii) the plane, or the plane parallel to the plane, of the planar end of the nozzle opposing the open end, which second stationary vane is closer to the open end than the first stationary vane, wherein the first stationary vane and the second stationary vane are devoid of another stationary vane therebetween, and wherein the first stationary vane and the second stationary vane are of the stationary vanes.
  • the nozzle is configured to hold an optical window on a closed end opposing the open end, and wherein the closed end is closed by the optical window.
  • the optical window is configured to facilitate entrance of an energy beam therethrough without (e.g., substantial) energetic loss.
  • the energy beam is a laser beam.
  • the optical window is configured to facilitate entrance of an energy beam therethrough, the energy beam having a processing cone, and wherein the inner surface of the nozzle has a shape configured to accommodate a portion of the processing cone of the energy beam (e.g., without obstruction).
  • the optical window is configured to facilitate entrance of an energy beam therethrough, the energy beam configured to generate a three-dimensional object using three-dimensional printing.
  • the three-dimensional printing includes printing one or more three- dimensional objects having a material comprising an elemental metal, a metal alloy, a ceramic, or an allotrope of elemental carbon.
  • the nozzle is configured to minimize debris from reaching the optical window during its operation.
  • the debris comprises byproduct generated during three-dimensional printing.
  • the debris comprises byproduct generated during soldering.
  • the debris comprises byproduct generated during sintering and/or melting.
  • the nozzle is a single (e.g., monolithic) object (e.g., the nozzle is a single component).
  • the nozzle is generated by three-dimensional printing comprising successive layers of deposited material.
  • the outer surface comprises holes, wherein holes in a first row are arranged in a staggered arrangement with rows of a second row that is immediately adjacent to the first row without an intervening row of holes.
  • the outer surface comprises holes arranged in parallel rows in a first direction, and rows arranged as a single file in a second direction.
  • the outer surface comprises holes arranged in parallel rows in a first direction, and rows arranged as single files in directions different from the first direction.
  • the nozzle is configured for directing flow of gas comprising an inert gas.
  • the device is configured to flow gas comprising an inert gas.
  • the device is configured to flow gas comprising a recycled and/or filtered gas.
  • the device is configured to flow gas comprising a gas flowing in a closed gas flow system.
  • the nozzle is configured for directing flow of gas comprising a lower concentration of a reactive agent as compared to an ambient atmosphere.
  • the reactive species comprises oxygen or humidity.
  • the reactive species is reactive with a starting material during a three-dimensional printing process.
  • the nozzle is configured for disposition in a casing.
  • the nozzle is configured to contact the casing though an intervening compressible seal.
  • the seal comprises an O-ring.
  • one or more ends of the nozzle comprise a groove configured to accommodate the compressible seal.
  • the nozzle is configured to contact the casing using solid to solid contact.
  • the nozzle has an opposing end to the open end, which opposing end is configured for solid-to- solid contact.
  • the opposing end has an exposed planar surface having a root mean square average of the roughness profile value of at most about 4 microinches, 8 microinches, 16 microinches, or 32 microinches.
  • the nozzle is configured to contact the casing using fasteners disposed adjacent to the open end.
  • the outer surface of the nozzle is configured to facilitate a (e.g., substantially) even flow of gas into the nozzle along the outer side surface.
  • the nozzle is configured to direct gas at a pressure above ambient pressure external to an enclosed environment in which the nozzle is disposed.
  • the enclosed environment is a processing chamber of a printer configured to print three- dimensional objects.
  • the nozzle is configured to operate at positive pressure above ambient pressure external to an enclosed environment in which the nozzle is disposed.
  • the enclosed environment is a processing chamber of a printer configured to print three-dimensional objects.
  • the stationary vanes comprise hollow tubes. In some embodiments, the hollow tubes are closely packed.
  • the hollow tubes are closely packed in a face centered cubic arrangement or in a cubic arrangement that is not face centered.
  • the stationary vanes comprise polygonal prisms having lateral sides, a missing first base facing the cavity of the nozzle, a second base comprising one or more holes disposed away from the cavity, the second base opposing the first base, the polygonal prisms being hollow, the polygonal prisms comprise a base that is a space filling polygon.
  • at least two immediately adjacent polygonal prisms have a common lateral side, the two immediately adjacent polygonal prisms are devoid of an intervening polygonal prism therebetween.
  • the device is configured to be coupled to an enclosure comprising (a) a gas inlet portion that includes at least one baffle configured to direct gas in a second direction different from the first direction, which gas is directed within the gas inlet portion, (b) a gas outlet portion having a cross-sectional shape that tapers toward the at least one outlet opening, or (c) any combination of (a) and (b).
  • the cross-sectional shape that tapers is configured to reduce turbulence, backflow, and/or standing vortices in a processing cone volume of an energy beam at least in part by tapering the flow of gas flowing through the enclosure, which processing cone is above a target surface or comprises the target surface disposed in the enclosure.
  • the device is configured to be coupled to a recessed portion of an enclosure, the recessed portion being relative to a first wall of the enclosure, which recessed portion comprises at least one optical window and a second wall of the enclosure that at least partially separates the recessed portion from the first wall, the at least one window and the second wall defining a volume of the recessed portion.
  • a method for gas flow comprising: (a) providing any of the devices above; and (b) using the device to flow the gas.
  • using the device is during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer.
  • a method for gas flow comprising: flowing gas through an outer side surface of a nozzle into an inner cavity of the nozzle and out of an open end of the inner cavity, the nozzle having the outer side surface opposing an inner side surface surrounding the inner cavity and comprising: (i) holes surrounding the inner cavity configured to facilitate the gas flow into the cavity, (ii) stationary vanes configured to direct the gas flow into the cavity and to the open end of the cavity, (iii) partitions configured to facilitate directing the gas into the cavity and to the open end of the cavity, (iv) the outer side surface having a first shape of a first side surface of a first truncated cone, and/or (v) an inner side surface having a second shape of a second side surface of a second truncated cone, which inner side surface is of the inner cavity.
  • an apparatus for gas flow comprising: at least one controller configured to: (a) operatively couple to any of the devices above; and (b) control, or direct control of, the gas flow by using the device.
  • the at least one controller is part of a hierarchical control system.
  • the hierarchical control system comprises at least three hierarchical control levels.
  • at least two operations are executed by the same controller of the at least one controller.
  • at least two operations are executed by different controllers of the at least one controller.
  • the at least one controller is configured to control, or direct control of, the gas flow by using the device during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer. In some embodiments, the at least one controller is configured to control, or direct control of, at least one component of the three-dimensional printer.
  • the at least one component comprises (i) an energy beam configured to facilitate printing one or more three-dimensional objects, (ii) a layer dispensing mechanism configured to dispense a layer of starting material for the three-dimensional printing, (iii) an elevation mechanism configured to translate a material bed in which one or more three-dimensional objects are printed, (iv) a material conveyance system configured to translate material in the three-dimensional printer, (v) a material recycling system configured to recycle unused material for usage in a subsequent printing cycle of three-dimensional printing, (vi) an optical system of the three-dimensional printer, or (vii) a sensor of the three- dimensional printer.
  • the optical system is configured to align energy beams of the three-dimensional printer.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the at least one controller is configured to (i) align or direct alignment of energy beams used in the three-dimensional printing, (ii) direct one or more energy beams to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detect, or direct detection of, any protrusion from an exposed surface of the material bed.
  • an apparatus for gas flow comprising at least one controller configured to: direct a flow of gas through an outer side surface of a nozzle into an inner cavity of the nozzle and out of an open end of the inner cavity, the nozzle having the outer side surface opposing an inner side surface surrounding the inner cavity and comprising: (i) holes surrounding the inner cavity configured to facilitate the gas flow into the cavity, (ii) stationary vanes configured to direct the gas flow into the cavity and to the open end of the cavity, (iii) partitions configured to facilitate directing the gas into the cavity and to the open end of the cavity, (iv) the outer side surface having a first shape of a first side surface of a first truncated cone, and/or (v) an inner side surface having a second shape of a second side surface of a second truncated cone, which inner side surface is of the inner cavity.
  • the at least one controller is configured to: (i) operatively couple to a gas conveyance system configured to facilitate the gas flow, and (ii) directs the gas conveyance system to convey the gas flow. In some embodiments, the at least one controller is configured to: (i) operatively couple to a gas source configured to generate the gas flow, and (ii) direct the source to generate the gas flow.
  • the one or more operations comprise controlling, or directing control of, the gas flow by using the device during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer. In some embodiments, the one or more operations comprise controlling, or directing control of, at least one component of the three-dimensional printer.
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors, cause the one or more processors to execute one or more operations comprising: directing a flow of gas through an outer side surface of a nozzle into an inner cavity of the nozzle and out of an open end of the inner cavity, the nozzle having the outer side surface opposing an inner side surface surrounding the inner cavity and comprising: (i) holes surrounding the inner cavity configured to facilitate the gas flow into the cavity, (ii) stationary vanes configured to direct the gas flow into the cavity and to the open end of the cavity, (iii) partitions configured to facilitate directing the gas into the cavity and to the open end of the cavity, (iv) a first truncated conical shape of the outer surface, and/or (v) a second truncated conical shape of the inner side surface.
  • a device for gas flow comprising: a main channel having an opening port, the main channel configured to direct gas flow; a first channel operatively coupled to the main channel, the first channel configured to direct the gas flow from the main channel to first one or more nozzles; a first baffle disposed in the first channel, the first baffle having a first gradient of openings (e.g., holes) that have a first total surface area; a second channel operatively coupled to the main channel, the second channel configured to direct gas from the main channel to second one or more nozzles, the second channel being disposed further away from the opening port as compared to the first channel; and a second baffle disposed in the second channel, the second baffle having a second gradient of openings (e.g., holes) that have a second total surface area larger than the first total surface area.
  • a first gradient of openings e.g., holes
  • the first planar cross section is at, or is parallel to, a first largest side of the first baffle
  • the first gradient and/or the second gradient comprises varied openings.
  • the different vertical cross sections comprise an oval, a circle, an oblong, or a rectangle.
  • the rectangle comprises rounded corners.
  • the first baffle and the second baffle have (e.g., substantially) the same circumference shape and/or dimensions.
  • the device is configured to flow gas at a pressure above ambient pressure external to an enclosure in which the device is disposed.
  • the enclosure is a processing chamber of a three-dimensional printer configured to print one or more three- dimensional objects.
  • the open pore (e.g., hole) may be part of an array of holes.
  • the open pore may be part of a cut pattern.
  • at least a portion of the device is printed in a three-dimensional printing process.
  • the at least a portion of the device comprises at least a portion of (i) the main channel, (ii) the first channel, (iii) the second channel, (iv) the first baffle, (v) the second baffle, or (vi) any combination of (i) (ii) (iii) (iv) and (v).
  • the device is configured to flow gas having a reactive species at a lower concentration as compared to an ambient atmosphere external to an enclosure in which the device is disposed.
  • the enclosure is a processing chamber of a three-dimensional printer configured to print one or more three- dimensional objects.
  • the reactive species comprises oxygen or humidity.
  • the reactive species is reactive with a starting material of a three-dimensional printing process.
  • the device is configured to flow gas comprising an inert gas.
  • the device is configured to flow gas comprising a gas flowing in a closed gas flow system.
  • the main channel is part of, or is operatively coupled to, a gas flow system of a three-dimensional printer.
  • the first one or more nozzles comprise first one or more optical windows and/or (ii) the second one or more nozzles comprise second one or more optical windows.
  • the nozzles are configured to direct flow of the gas away from the optical windows.
  • the first one or more nozzles direct the flow in a direction away from the one or more nozzles towards a target surface and/or (ii) the second one or more nozzles direct the flow in a direction away from the one or more nozzles towards the target surface.
  • the target surface comprises (a) a floor of a processing chamber or (b) an exposed surface of a material bed.
  • the first baffle is configured to receive a first incoming gas flow through the first channel and generate a first out flow of the gas, wherein a gradient in a direction from the opening port to the first baffle is reduced in the first out flow of the gas as compared to the gradient in the first incoming gas flow and/or (b) the second baffle is configured to receive a second incoming gas flow through the second channel and generate a second out flow of the gas, wherein a gradient in a direction from the opening port to the second baffle is reduced in the second out flow of the gas as compared to the gradient in the second incoming gas flow.
  • the first baffle extends to a cross section of the first channel and/or (ii) the second baffle extends to a cross section of the second channel.
  • the first gradient of openings comprises a circular cross sectioned opening and/or (ii) the second gradient of openings comprises a circular cross sectioned opening.
  • the first gradient of openings comprises a polygonal cross sectioned opening and/or (ii) the second gradient of openings comprises a polygonal cross sectioned opening.
  • the polygonal cross sectioned opening comprise rounded corners.
  • the device includes a material comprising elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon.
  • the device includes components comprising the first channel, the first baffle, the second channel, the second baffle, and the main channel, and wherein at least one component of the components includes a material comprising elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon.
  • the first gradient of openings comprises a rectangular cross sectioned opening and/or (ii) the second gradient of openings comprises a rectangular cross sectioned opening.
  • the first gradient of openings comprises a first gradient of polygonal cross sectioned openings having (e.g., substantially) the same height and/or (ii) the second gradient of openings comprises a second gradient of polygonal cross sectioned openings having (e.g., substantially) the same height.
  • the first gradient of openings comprises a first gradient of polygonal cross sectioned openings having varied widths and/or (ii) the second gradient of openings comprises a second gradient of polygonal cross sectioned openings having varied widths.
  • the first gradient of openings comprises a first gradient of polygonal cross sectioned openings separated by a first gap and/or (ii) the second gradient of openings comprises a second gradient of polygonal cross sectioned openings separated by a second gap.
  • the first gap is equal to the second gap.
  • the first gap is different from the second gap.
  • the second gap is smaller than the first gap.
  • the first gradient of openings comprises a first number of openings and/or (ii) the second gradient of openings comprises a second number of openings.
  • the first number is equal to the second number.
  • the first number is different from the second number.
  • the second number is larger than the first number.
  • a method for gas flow comprising: (a) providing any of the devices above; and (b) using the device to flow the gas.
  • using the device is during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer.
  • a method for gas flow comprising: directing a gas flow from an opening port through a main channel; the gas flow is directed from the main channel through a first channel to first one or more nozzles, wherein a first baffle, having a first gradient of openings that have a first total surface area, is disposed in the first channel; and the gas flow is directed from the main channel through a second channel, which second channel is disposed further away from the opening port as compared to the first channel, to a second one or more nozzles, wherein the second baffle, having a second gradient of openings that have a second total surface area larger than the first total surface area, is disposed in the second channel.
  • an apparatus for gas flow comprising: at least one controller configured to: (a) operatively couple to any of the devices above; and (b) control, or direct control of, the gas flow by using the device.
  • the at least one controller is part of a hierarchical control system.
  • the hierarchical control system comprises at least three hierarchical control levels.
  • at least two operations are executed by the same controller of the at least one controller.
  • at least two operations are executed by different controllers of the at least one controller.
  • the at least one controller is configured to control, or direct control of, the gas flow by using the device during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer. In some embodiments, the at least one controller is configured to control, or direct control of, at least one component of the three-dimensional printer.
  • the at least one component comprises (i) an energy beam configured to facilitate printing one or more three-dimensional objects, (ii) a layer dispensing mechanism configured to dispense a layer of starting material for the three-dimensional printing, (iii) an elevation mechanism configured to translate a material bed in which one or more three-dimensional objects are printed, (iv) a material conveyance system configured to translate material in the three-dimensional printer, (v) a material recycling system configured to recycle unused material for usage in a subsequent printing cycle of three-dimensional printing, (vi) an optical system of the three-dimensional printer, or (vii) a sensor of the three- dimensional printer.
  • the optical system is configured to align energy beams of the three-dimensional printer.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the at least one controller is configured to (i) align or direct alignment of energy beams used in the three-dimensional printing, (ii) direct one or more energy beams to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detect, or direct detection of, any protrusion from an exposed surface of the material bed.
  • an apparatus for gas flow comprising at least one controller configured to: direct a gas flow from an opening port through a main channel; the flow of gas is directed from the main channel through a first channel to first one or more nozzles, wherein a first baffle, having a first gradient of openings that have a first total surface area, is disposed in the first channel; and the flow of gas is directed from the main channel through a second channel, which second channel is disposed further away from the opening port as compared to the first channel, to a second one or more nozzles, wherein the second baffle, having a second gradient of openings that have a second total surface area larger than the first total surface area, is disposed in the second channel.
  • the at least one controller is configured to: (i) operatively couple to a gas conveyance system configured to facilitate the gas flow, and (ii) direct the gas conveyance system to convey the gas flow. In some embodiments, the at least one controller is configured to: (i) operatively couple to a source configured to generate the gas flow, and (ii) direct the source to generate the gas flow.
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors operatively coupled to any of the devices above, cause the one or more processors to execute one or more operations comprising controlling, or directing control of, the gas flow by using the device.
  • the one or more processors are part of a hierarchical control system.
  • the hierarchical control system comprises at least three hierarchical control levels.
  • at least two operations are executed by the same processor of the one or more processors.
  • at least two operations are executed by different processors of the processor of the one or more processors.
  • the one or more operations comprise controlling, or directing control of, the gas flow by using the device during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer. In some embodiments, the one or more operations comprise controlling, or directing control of, at least one component of the three-dimensional printer.
  • the at least one component comprises (i) an energy beam configured to facilitate printing one or more three-dimensional objects, (ii) a layer dispensing mechanism configured to dispense a layer of starting material for the three-dimensional printing, (iii) an elevation mechanism configured to translate a material bed in which one or more three-dimensional objects are printed, (iv) a material conveyance system configured to translate material in the three-dimensional printer, (v) a material recycling system configured to recycle unused material for usage in a subsequent printing cycle of three-dimensional printing, (vi) an optical system of the three-dimensional printer, or (vii) a sensor of the three-dimensional printer.
  • the optical system is configured to align energy beams of the three- dimensional printer.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the one or more operations comprise (i) aligning or directing alignment of energy beams used in the three-dimensional printing, (ii) directing one or more energy beam to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detecting, or directing detection of, any protrusion from an exposed surface of the material bed.
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors, cause the one or more processors to execute one or more operations comprising: directing a gas flow from an opening port through a main channel; the gas flow is directed from the main channel through a first channel to first one or more nozzles, wherein a first baffle, having a first gradient of openings that have a first total surface area, is disposed in the first channel; and the gas flow is directed from the main channel through a second channel, which second channel is disposed further away from the opening port as compared to the first channel, to a second one or more nozzles, wherein the second baffle, having a second gradient of openings that have a second total surface area larger than the first total surface area, is disposed in the second channel.
  • the one or more processors are operatively coupled to a gas conveyance system configured to facilitate the gas flow, and wherein the operations comprise directing the gas conveyance system to convey the gas flow. In some embodiments, the one or more processors are operatively coupled to a source configured to generate the gas flow, and wherein the operations comprise directing the source to generate the gas flow.
  • a device for gas flow comprising: a casing comprising: a first face having a first set of openings; a second face opposing the first one face comprising a second set of openings; one or more side panels connecting the first face to the second face; an ingress port disposed at a side panel of the one or more side panels and configured to facilitate gas flow through the ingress port; the first set of openings and the second set of openings configured to couple to nozzles configured to facilitate egress of the gas entering from the ingress port to the casing having the nozzles distributed in the casing away from the ingress port; and the casing configured to couple to a baffle disposed in the casing between the ingress port and the nozzles, the baffle configured to facilitate evening (e.g., equalizing) the gas flowing from the ingress port to the nozzles and/or (ii) which casing tapers in a direction from the ingress port towards the most distant nozzle from the ingress port, which most distance
  • the device is configured to flow gas having a reactive species at a lower concentration as compared to an ambient atmosphere external to an enclosure in which the device is disposed.
  • the enclosure is a processing chamber of a three-dimensional printer configured to print one or more three-dimensional objects.
  • the reactive species comprises oxygen or humidity.
  • the reactive species is reactive with a starting material of a three-dimensional printing process.
  • a build module is configured to accommodate a material bed in which at least one three-dimensional object is printed (e.g., in a printing cycle), and (e.g., reversibly) couple to the processing chamber.
  • the material bed and/or the build module may have a FLS of at least about 300mm, 400mm, 500mm, 600mm, or 1000mm.
  • the at least one three-dimensional objects may comprise a cavity, an open hole, a protrusion (e.g., pin), a shallow ledge, a steep ledge, or a cavity (e.g., having a curvature).
  • the at least one three-dimensional objects may comprise a thin wall or thin engraving.
  • the open pore (e.g., hole) may be part of an array of holes.
  • the open pore may be part of a cut pattern.
  • the device is configured to flow gas comprising an inert gas.
  • the device is configured to flow gas comprising a recycled and/or filtered gas. In some embodiments, the device is configured to flow gas comprising a gas flowing in a closed gas flow system. In some embodiments, the device includes a material comprising elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon. In some embodiments, the device includes components comprising the first face, the second face, the one or more side panels, and the nozzles, and wherein at least one component of the components includes a material comprising elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon. In some embodiments, the nozzles are distributed in the casing successively in a direction away from the ingress port.
  • the device comprises the baffle disposed in the casing between the ingress port and the nozzles.
  • the baffle is configured to direct flow from the ingress port to the nozzles.
  • the baffle is configured to direct flow from the ingress port to the nozzles in a non-turbulent flow and/or non-back flow.
  • the baffle is configured to direct flow from the ingress port to the nozzles with minimal turbulence and/or back flow.
  • the baffle is configured to direct flow to engulf the nozzles in the casing.
  • the baffle is configured to reduce flow of the gas from the ingress port to the nozzles.
  • the baffle comprises openings (e.g., holes) that facilitate gas flow through the baffle.
  • the openings are disposed in a random pattern along the baffle.
  • the openings are disposed in a gradient pattern along the baffle.
  • the gradient comprises a linear gradient.
  • the gradient comprises an exponential gradient.
  • the openings are at a higher concentration further away from the ingress port.
  • the openings are disposed in a non-repetitive manner along the baffle.
  • the openings are disposed in a repeating pattern along the baffle.
  • the repeating pattern comprises a cubic pattern. In some embodiments, the repeating pattern comprises a face centered cubic pattern. In some embodiments, an opening of the openings has a fundamental length scale that is at most about 5, 10, 20, 25, 30, or 40 percent of the fundamental length scale of the repetition of the repeating pattern. In some embodiments, the repeating pattern comprises a hexagonal pattern. In some embodiments, the casing tapers in the direction from the ingress port towards the most distant nozzle from the ingress port, which most distant nozzle is of the one or more nozzles. In some embodiments, the nozzles are disposed in the casing such that gas can evenly flow around the nozzle.
  • the nozzles are disposed in the casing such that gas can evenly flow from the nozzles and away from the casing in a direction from the first face to the second face. In some embodiments, the nozzles are disposed in the casing with a gap between the nozzles and the one or more side panels. In some embodiments, the nozzles are disposed in the casing without contacting the one or more side panels. In some embodiments, first ends of the nozzles are coplanar with the first face. In some embodiments, the nozzles are closed at their first ends contacting with the first face. In some embodiments, the nozzles are capped at their first ends with optical windows. In some embodiments, the nozzles are configured to direct flow of the gas away from the optical windows.
  • second ends of the nozzles are coplanar with the second face.
  • the nozzles are open at their second ends contacting with the second face, and configured to direct flow of the gas through their second ends that are open.
  • the casing tapers linearly.
  • a height of the nozzles and/or of the one or more side panels is (e.g., substantially) the same. In some embodiments, the nozzles are (e.g., substantially) the same.
  • the casing includes a tapered portion, and wherein a tip of the tapered portion contacts an end of the baffle. In some embodiments, the one or more side panels, the first face, and/or the second face comprise a curvature where the casing tapers. In some embodiments, the baffle extends from the first face to the second face. In some embodiments, the nozzles are disposed away from the baffle and adjacent to one side of the device.
  • a method for gas flow comprising: flowing gas through an ingress port disposed at a side panel of one or more side panels connecting a first face to a second face of a casing, which first face has a first set of openings and which second face has a second set of openings; gas flow is egressed from the ingress port through nozzles, which nozzles are distributed in the casing away from the ingress port and are coupled to the first set of openings and the second set of openings; and the gas flow is being evened out from the ingress port to the nozzles at least in part by (i) baffles disposed in the casing between the ingress port and the nozzles, the baffle configured to facilitate evening (e.g., equalizing) the gas flowing from the ingress port to the nozzles and/or (ii) a taper in the casing, which taper is in a direction from the ingress port towards a most distant of the nozzles from the ingress port.
  • an apparatus for gas flow comprising: at least one controller configured to: (a) operatively couple to any of the devices above; and (b) control, or direct control of, the gas flow by using the device.
  • the at least one controller is part of a hierarchical control system.
  • the hierarchical control system comprises at least three hierarchical control levels.
  • at least two operations are executed by the same controller of the at least one controller.
  • at least two operations are executed by different controllers of the at least one controller.
  • the at least one controller is configured to control, or direct control of, the gas flow by using the device during three-dimensional printing by a three-dimensional printer, and wherein the device is part of, or is operatively coupled to, a three-dimensional printer. In some embodiments, the at least one controller is configured to control, or direct control of, at least one component of the three-dimensional printer.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the at least one controller is configured to (i) align or direct alignment of energy beams used in the three-dimensional printing, (ii) direct one or more energy beams to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detect, or direct detection of, any protrusion from an exposed surface of the material bed.
  • an apparatus for gas flow comprising at least one controller configured to: direct gas flow through an ingress port disposed at a side panel of one or more side panels connecting a first face to a second face of a casing, which first face has a first set of openings and which second face has a second set of openings; the gas flow is egressed from the ingress port through nozzles, which nozzles are distributed in the casing away from the ingress port and are coupled to the first set of openings and the second set of openings; and the gas flow is being evened out from the ingress port to the nozzles at least in part by (i) baffles disposed in the casing between the ingress port and the nozzles, the baffle configured to facilitate evening (e.g., equalizing) the gas flowing from the ingress port to the nozzles and/or (ii) a taper in the casing, which taper is in a direction from the ingress port towards a most distant of the nozzles
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors operatively coupled to any of the devices above, cause the one or more processors to execute one or more operations comprising controlling, or directing control of, the gas flow by using the device.
  • the one or more processors are part of a hierarchical control system.
  • the hierarchical control system comprises at least three hierarchical control levels.
  • at least two operations are executed by the same processor of the one or more processors.
  • at least two operations are executed by different processors of the processor of the one or more processors.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the one or more operations comprise (i) aligning or directing alignment of energy beams used in the three-dimensional printing, (ii) directing one or more energy beam to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detecting, or directing detection of, any protrusion from an exposed surface of the material bed.
  • the at least one three-dimensional objects may comprise a cavity, an open hole, a protrusion (e.g., pin), a shallow ledge, a steep ledge, or a cavity (e.g., having a curvature).
  • the at least one three-dimensional objects may comprise a thin wall or thin engraving.
  • the open pore e.g., hole
  • the open pore may be part of an array of holes.
  • the open pore may be part of a cut pattern.
  • the device is configured to flow gas comprising an inert gas.
  • the device is configured to flow gas comprising a recycled and/or filtered gas.
  • the device is configured to flow gas comprising a gas flowing in a closed gas flow system.
  • the connecter comprises a rod, a column, or a plank.
  • the actuator is configured to toggle between the first opening and the second opening at a speed of at most about 0.1 , 0.25, 0.5, 0.75, or 0.9 seconds per toggle (e.g., switch, alter, or change).
  • the actuator is configured for control by one or more controllers.
  • the one or more controllers are configured to control printing of one or more three-dimensional objects in a printing cycle.
  • the one or more controllers are configured to at least one component of a three-dimensional printer.
  • the device is a component of the three-dimensional printer, and the at least one component exclude the device.
  • the at least one component comprise an energy beam, a directing component of the energy beam, an elevator mechanism of a build plate, a layer dispensing mechanism, a material recycling system, a material conveyance system, a gas conveyance system, any component thereof, or any component associated therewith.
  • the device comprises a railing, and wherein the plate is configured to slide along the railing. In some embodiments, at least a portion of the plate is inserted into the first channel and into the second channel. In some embodiments, the device comprises at least one seal disposed between (i) the plate and (ii) the first channel and the second channel.
  • the plate is a first plate
  • the device comprises a second plate including a third openings having a fundamental length scale of the first channel, and a fourth opening having a fundamental length scale of the second channel, which second plate is configured to engage the third opening with the first channel, and the fourth opening with the second channel, and wherein the first plate slides relative to the first plate.
  • the at least one seal disposed between the first plate and the second plate.
  • the device comprises a third plate similar to the second plate, and wherein the first plate is enclosed within a compartment generated by joining the second plate to the third plate.
  • the director valve comprises a railing, and wherein the plate is configured to slide along the railing.
  • the foam comprises a polymer, a resin, an elemental metal, a metal alloy, a ceramic, or an allotrope of elemental carbon. In some embodiments, the foam comprises cellulose or polyurethane. In some embodiments, the first flow directing component and/or the second flow directing component comprises distributed openings. In some embodiments, the first flow directing component and/or the second flow directing component comprises repetitively distributed openings. In some embodiments, the first flow directing component and/or the second flow directing component comprises randomly and/or non-repetitively distributed openings. In some embodiments, the first flow directing component and/or the second flow directing component comprises a mesh.
  • the first flow directing component and/or the second flow directing component comprises hollow prisms having a cross section of space filling polygons.
  • the first flow directing component and/or the second flow directing component comprises hollow tubes.
  • the hollow tubes are closely packed.
  • the hollow tubes are closely packed in a face centered cubic arrangement or in a cubic arrangement that is not face centered.
  • the first flow directing component and/or the second flow directing component facilitate laminar flow along an exposed surface of a material bed disposed at a floor of the chamber and/or along one or more optical windows disposed in a roof of the chamber.
  • the first flow directing component and/or the second flow directing component is configured to minimize back flow of the gas to one or more optical windows disposed in a roof of the chamber. In some embodiments, minimizing the back flow of the gas is during printing of one or more three-dimensional objects in a printing cycle.
  • the device is configured to facilitate varying the gas flow in the first gas ingress opening as compared to that in the second gas ingress opening. In some embodiments, the device is configured to facilitate varying the gas flow depending on a process type occurring in the chamber.
  • the process type comprises (i) printing one or more three-dimensional objects in a printing cycle using at least one energy beam, or (ii) depositing a planar layer of starting material to form a material bed from which the one or more three-dimensional objects are printed in a printing cycle.
  • varying the gas flow comprises (i) varying an intensity of the gas flow, or (i) varying between gas flow and no gas flow.
  • the device facilitates greater gas flow through the first gas ingress opening as compared to the gas flow through the second gas ingress opening during printing one or more three-dimensional objects in a printing cycle using at least one energy beam; and wherein as compared to the second gas ingress opening, the first gas ingress opening is disposed (I) closer to a floor of the chamber and/or an exposed surface of a material bed disposed in the chamber and/or (II) further away from an optical window through which one or more energy beams enter the optical window to print the one or more three-dimensional objects in the printing cycle. In some embodiments, the there is no gas flowing through the second gas ingress opening.
  • the device facilitates greater gas flow through the second gas ingress opening as compared to the gas flow through the second gas ingress opening during deposition of a planar layer of starting material to form a material bed from which one or more three-dimensional objects are printed in a printing cycle; and wherein as compared to the second gas ingress opening, the first gas ingress opening is disposed (I) closer to a floor of the chamber and/or an exposed surface of a material bed disposed in the chamber and/or (II) further away from an optical window through which one or more energy beams enter the optical window to print the one or more three-dimensional objects in the printing cycle. In some embodiments, there is no gas flowing through the first gas ingress opening.
  • toggling the plate of the director valve results at least in part in (i) varying the first gas flow flowing through the first opening of the director valve and/or (ii) varying the second gas flow flowing through the second opening of the director valve.
  • the first gas flow flowing through the first opening is equal, or substantially equal, to the second gas flow flowing through the second opening.
  • the first gas flow flowing through the first opening differs from the second gas flow flowing through the second opening.
  • varying the first gas flow through the first opening and varying the second gas flow through the second channel comprises stopping the first gas flow and/or the second gas flow.
  • varying the first gas flow through the first opening and varying the second gas flow through the second channel comprises reducing an intensity of the first gas flow and/or the second gas flow as compared to their flow in the first channel and/or second channel, respectively. In some embodiments, varying the first gas flow through the first opening and varying the second gas flow through the second channel comprises reducing a throughput of the first gas flow and/or the second gas flow as compared to their flow in the first channel and/or second channel, respectively.
  • the at least one component comprises (i) an energy beam configured to facilitate printing one or more three-dimensional objects, (ii) a layer dispensing mechanism configured to dispense a layer of starting material for the three-dimensional printing, (iii) an elevation mechanism configured to translate a material bed in which one or more three-dimensional objects are printed, (iv) a material conveyance system configured to translate material in the three-dimensional printer, (v) a material recycling system configured to recycle unused material for usage in a subsequent printing cycle of three-dimensional printing, (vi) an optical system of the three-dimensional printer, or (vii) a sensor of the three- dimensional printer.
  • the optical system is configured to align energy beams of the three-dimensional printer.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the at least one controller is configured to (i) align or direct alignment of energy beams used in the three-dimensional printing, (ii) direct one or more energy beams to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detect, or direct detection of, any protrusion from an exposed surface of the material bed.
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors operatively coupled to any of the devices above, cause the one or more processors to execute one or more operations comprising controlling, or directing control of, the gas flow by using the device.
  • the one or more processors are part of a hierarchical control system.
  • the hierarchical control system comprises at least three hierarchical control levels.
  • at least two operations are executed by the same processor of the one or more processors.
  • at least two operations are executed by different processors of the processor of the one or more processors.
  • the optical system is configured to detect any protrusion from an exposed surface of the material bed.
  • the one or more operations comprise (i) aligning or directing alignment of energy beams used in the three-dimensional printing, (ii) directing one or more energy beam to irradiate and translate along the material bed to print the one or more three-dimensional objects, and/or (iii) detecting, or directing detection of, any protrusion from an exposed surface of the material bed.
  • a non-transitory computer readable program instructions for gas flow the program instructions, when read by one or more processors operatively coupled to a director valve, cause the one or more processors to execute one or more operations comprising: directing a first gas flow through a first channel, which first channel is connected to a first gas ingress opening of a chamber; directing a second gas flow through a second channel, which second channel is connected to a second gas ingress opening of the chamber; and directing toggling of a plate of the director valve, coupled to the first channel and the second channel, between a first opening and a second opening that vary directing of the first gas flow through the first channel and of the second gas flow through the second channel, which first opening has a first cross section and which second opening has a second cross section.
  • operations comprise toggling the plate of the director valve such that (i) varying the first gas flow flowing through the first opening of the director valve and/or (ii) varying the second gas flow flowing through the second opening of the director valve.
  • the first gas flow flowing through the first opening is equal, or substantially equal, to the second gas flow flowing through the second opening.
  • the one or more symmetry planes comprise a plane perpendicular to the plane of the ceiling.
  • the one or more rotational axes comprise (i) a rotational axis parallel to the plane of the ceiling and/or (ii) a rotational axis disposed at the plane of the ceiling.
  • the one or more rotational axes comprise a rotational axis perpendicular to the plane of the ceiling.
  • the inversion symmetry point is disposed (i) at the elongated two-dimensional geometric shape and/or (ii) at the plane of the ceiling.
  • At least one of the optical windows is held by a window holder comprising a nozzle configured to direct gas into the enclosure and away from the optical window.
  • each of the optical windows is held by a window holder comprising a nozzle configured to direct gas into the enclosure and away from the optical window.
  • the optical windows are held by window holders that form an arrangement of window holders.
  • the window holders of the arrangement of window holders are symmetrically related using (i) one or more mirror symmetry planes other than the plane of the ceiling, (ii) one or more rotational axes, and/or (iii) an inversion symmetry point.
  • the one or more rotational axes comprises a 180 degrees rotational symmetry axis (C2 symmetry axis).
  • the one or more symmetry planes comprise a plane perpendicular to the plane of the ceiling.
  • the one or more rotational axes comprise (I) a rotational axis parallel to the plane of the ceiling and/or (II) a rotational axis disposed at the plane of the ceiling.
  • the one or more rotational axes comprise a rotational axis perpendicular to the plane of the ceiling.
  • the inversion symmetry point is disposed (i) at the elongated two-dimensional geometric shape and/or (ii) at the plane of the ceiling.
  • the symmetrical relation of the window holders of the arrangement of window holders is devoid of (i) an inversion point, (ii) a rotational axis disposed in the plane of the ceiling and/or (iii) a rotational axis disposed in a plane parallel to the plane of the ceiling.
  • a window holder of the window holders comprises a gas nozzle configured to guide the gas to flow into an interior space of the window holder, in a direction away from the optical window. In some embodiments, away is in a direction opposing the optical window.
  • the window holder has a circular horizontal cross section. In some embodiments, the window holder comprises a hollow interior. In some embodiments, the window holder is configured to hold the window at least in part by encircling a circumference of the optical window. In some embodiments, the window holder comprises a hollow truncated cone, a hollow tube, or a hollow prism. In some embodiments, the window holder comprises holes configured to facilitate flow of gas therethrough from an exterior of the window holder to an interior of the window holder. In some embodiments, the window holder comprises stationary vanes configured to guide flow of gas therethrough from an exterior of the window holder to an interior of the window holder to an opening of the window holder in a direction.
  • the window holder is configured to hold a window on one of its open ends that is a first open end, and wherein the stationary vanes are configured to direct the flow of gas to a second open end of the window holder, the second open end opposing the first open end.
  • the window holder is generated using three-dimensional printing.
  • the window holder comprises elemental metal, metal alloy, a ceramic, or an allotrope of elemental carbon.
  • the enclosure is configured to hold an atmosphere having (i) an atmosphere having pressure above ambient pressure external to the enclosure, and/or (ii) the atmosphere having a reactive agent at a lower concentration as compared to its concentration in the ambient atmosphere external to the enclosure.
  • the reactive agent is reactive with a starting material of three-dimensional printing during the printing.
  • the reactive agent comprises oxygen or water (e.g., humidity).
  • the enclosure is a processing chamber of a three-dimensional printing system.
  • the enclosure is utilized to generate (e.g., print) at least one window holder of an optical window.
  • a method of transmitting radiation comprises: providing the device in any of the above devices; and using the device to transmit the radiation through at least one of the optical windows into the enclosure.
  • a method of transmitting radiation comprising: (a) providing an arrangement of optical windows disposed on a ceiling of an enclosure, which optical windows are arranged along a plane of the ceiling, the optical windows disposed along a circumference of an elongated two-dimensional geometric shape, the optical windows comprising three or more optical windows; and (b) using the arrangement of optical windows to transmit the radiation through at least one of the optical windows into the enclosure.
  • a non-transitory computer readable program instructions for transmitting radiation the program instructions, when read by one or more processors operatively couples to at least one guidance system, direct the at least one guidance system to transmit the radiation through at least one optical window of the arrangement of optical windows using the device in any of the above devices to transmit the radiation through at least one of the optical windows into the enclosure.
  • an non-transitory computer readable program instructions for transmitting radiation when read by one or more processors operatively couples to at least one guidance system, direct the one or more processors to execute one or more operations comprising: directing the at least one guidance system to transmit the radiation through at least one of the optical windows into the enclosure at least in part by using an arrangement of optical windows disposed on a ceiling of an enclosure, which optical windows are arranged along a plane of the ceiling, the optical windows disposed along a circumference of an elongated two-dimensional geometric shape, the optical windows comprising three or more optical windows.
  • the gas flow velocity direction along at least one of a height or a depth of the enclosure is substantially constant as the gas flows through at least the processing cone, during at least the transformation.
  • the gas flows through the processing cone is free of at least one of (1 ) a recirculation, (2) flow stagnation, and (3) static vortex of the gas.
  • the gas flows through the processing cone in a non-turbulent flow.
  • the gas flows through the processing cone in a non-stagnant flow.
  • the gas flows through the processing cone in a non-circulatory flow.
  • the first side comprises an internal wall disposed between the material bed and the inlet opening.
  • the internal wall comprises a filter.
  • the filter is a High-Efficiency Particulate Arrestance (HEPA) filter.
  • the internal wall comprises an opening.
  • the internal wall comprises a perforated plate.
  • the internal wall comprises a flow aligning passage.
  • the enclosure comprises a baffle between the inlet opening and the internal wall.
  • the internal wall comprises a ledge.
  • the internal wall comprises a ledge and a perforated plate.
  • the gas flow may alter an amount of debris in an atmosphere of the enclosure. In some embodiments, alter is reduce. In some embodiments, the gas flow removes an amount of debris in an atmosphere of the enclosure. In some embodiments, the operation of removal (e.g., the remove) is during at least a portion of the 3D printing. In some embodiments, the gas flow flows during at least a portion of the 3D printing. In some embodiments, at least a portion of the 3D printing comprises during the operation of the energy beam. In some embodiments, during the operation of the energy beam comprises during the transforming.
  • the system further comprises a recycling mechanism that treats (e.g., filters and/or removes a reacting species (e.g., oxygen and/or humidity)) the gas that flows from the outlet opening.
  • the recycling mechanism comprises a valve.
  • the recycling mechanism is fluidly connected (e.g., allows flow therethrough, e.g., flow of gas and/or liquid) to the outlet opening.
  • the recycling mechanism is fluidly connected to the inlet opening.
  • the recycling mechanism filters the gas that enters the recycling mechanism, from a debris.
  • the recycling mechanism removes a reactive species from the gas that enters the recycling mechanism.
  • the recycling mechanism outputs a gas with a reduced amount of a debris. In some embodiments, the recycling mechanism may output a gas with a reduced concentration of a reactive species. In some embodiments, at least one controller is further operatively coupled to the recycling mechanism and may direct the recycling mechanism to recycle the gas that is evacuated from the enclosure. In some embodiments, treating is during at least a portion of the 3D printing. In some embodiments, treating is continuous during at least a portion of the 3D printing. In some embodiments, the recycling mechanism comprises a gas composition sensor. In some embodiments, the recycling mechanism comprises a pump. In some embodiments, the pump comprises a variable frequency drive to control the flow of gas. In some embodiments, at least one controller is a plurality of controllers.
  • the material bed comprises at least one particulate material that is selected from the group consisting of an elemental metal, metal alloy, ceramic, and an allotrope of elemental carbon.
  • the 3D printing is additive manufacturing.
  • the additive manufacturing comprises selective laser sintering or selective laser melting.
  • the energy beam comprises electromagnetic or charged particle radiation.
  • the energy beam comprises a laser beam.
  • the gas comprises argon.
  • a method for generating a 3D object comprising: (a) using an energy beam to transform a portion of a material bed to a transformed material to form at least a portion of the 3D object, wherein the material bed is disposed in an enclosure, wherein the enclosure has a first enclosure side and a second enclosure side that opposes the first enclosure side, wherein the material bed is disposed between the first enclosure side and the second enclosure side, wherein between is inclusive, wherein the energy beam occupies a processing cone volume within the enclosure and above the material bed during the using; and (b) flowing a gas through the processing cone from the first enclosure side, to the second enclosure side which gas exits the enclosure, wherein the gas flow has a velocity direction along a width of the enclosure, which velocity direction of the gas flow remains unchanged during the gas flow through at least the processing cone.
  • the gas flows through at least the processing cone without forming (at least in the processing cone volume) at least one of (1 ) a recirculation, (2) flow stagnation, and (3) static vortex, of the gas.
  • the gas flows aerodynamically at least in the processing cone.
  • the phrase “at least in the processing cone” comprises a first enclosure volume that is from the first enclosure side to the processing cone.
  • the phrase “at least in the processing cone” comprises a second enclosure volume that is from the processing cone to the second enclosure side.
  • the phrase “at least in the processing cone” comprises the entire processing chamber and/or enclosure volume.
  • the method further comprises recycling the gas out of (e.g., externally to) the enclosure from the second enclosure side. In some embodiments, the method further comprises recycling the gas out of the enclosure from the second enclosure side, and into the enclosure through the first enclosure side. In some embodiments, the method further comprises treating the gas that flows out of the enclosure from the second enclosure side. In some embodiments, treating comprises filtering the gas from a debris. In some embodiments, treating comprises removing a reactive species from the gas that flows from the outlet opening.
  • an apparatus for 3D printing comprising at least one controller that is programmed to perform operations: operation (a) direct an energy beam from an energy source to a material bed to transform at least a portion of the material bed to a transformed material and form the 3D object, wherein the material bed is disposed in an enclosure, wherein the enclosure has a first enclosure side and a second enclosure side opposing the first enclosure side, wherein the material bed is disposed between the first opposing side and the second opposing side, wherein between is inclusive; and operation (b) direct a gas flow from the first enclosure side through a processing cone, to the second enclosure side, which processing cone is an enclosure volume that the energy beam occupies during the transform, which gas flow has a velocity direction, wherein the velocity direction of the gas flow along a width of the enclosure remains unchanged during the gas flow through at least the processing cone.
  • the flow of gas through at least the processing cone volume is devoid of at least one of (1 ) a recirculation, (2) flow stagnation, and (3) static vortex.
  • at least one controller is a multiplicity of controllers and wherein at least two of operations (a), and (b) is directed by the same controller.
  • at least one controller is a multiplicity of controllers and wherein at least two of operations (a), and (b) is directed by the different controllers.
  • the controller directs a first valve to control the gas that enters the first enclosure side.
  • the controller directs a second valve to control the gas that exits the second enclosure side.
  • the controller controls at least one of the makeup, density, trajectory, and velocity of the gas that enters the enclosure.
  • the trajectory of a flow of the gas is linear. In some embodiments, the trajectory is linear in one or more of: the height, depth, and width of the enclosure. In some embodiments, at least in the processing cone, the trajectory of a flow of the gas is smooth. In some embodiments, the trajectory is smooth in one or more of: the height, depth, and width of the enclosure.
  • a method for printing a 3D object comprises, during the 3D printing: (a) flowing at least one gas at a velocity through a gas flow mechanism, which at least one gas is inserted to the gas flow mechanism through an opening in the gas flow mechanism, which gas is inert with respect to the material used or produced in a 3D printing of the 3D object; (b) maintaining the pressure of the at least one gas in the gas flow mechanism to above an ambient atmospheric pressure; and (c) maintaining a low level of a reactive agent in the gas flow mechanism, which low level is below a violent reaction level of the reactive agent with the material used or produced during the 3D printing, wherein the material used or produced during the 3D printing reacts violently at an ambient atmosphere flowing at the velocity.
  • the violent reaction is an exothermic reaction.
  • the violent reaction comprises combustion, ignition, or flaming.
  • the gas flow mechanism comprises a channel, chamber, valve, or a pump.
  • maintaining the pressure comprises limiting occurrence of a negative pressure with respect to the ambient atmospheric pressure in at least one section of the gas flow mechanism.
  • at least one section of the gas flow mechanism comprises an area adjacent to the pump.
  • at least one section of the gas flow mechanism comprises an area behind the pump relative to the direction of gas flow.
  • maintaining the pressure comprises raising the pressure of the at least one gas in the gas flow mechanism.
  • maintaining the pressure comprises purging of at least one reactive agent from the gas flow mechanism.
  • purging comprises opening, closing, or adjusting one or more valves.
  • purging comprises opening at least one inlet-purge-valve to insert at least one gas into the gas flow mechanism, and opening at least one outlet-purge-valve to evacuate at least one reactive agent from the gas flow mechanism and reach a low level of the reactive agent in the gas flow mechanism.
  • a least one gas is an inert gas with respect to the material used or produced in the 3D printing.
  • the method further comprises opening at least one inlet modulating-valve and at least one outlet modulating-valve to maintain or reduce the low level of the reactive agent in the gas flow mechanism.
  • maintaining or reducing the low level of the reactive agent in the gas flow mechanism comprises inserting at least one gas into the gas flow mechanism through the inlet modulating valve, and expelling the reactive agent through the outlet modulating valve.
  • at least two of: the inlet purge-valve, outlet purge-valve, inlet modulating-valve, and outlet modulating-valve have the same cross section.
  • At least two of the inlet purge-valve, outlet purge-valve, inlet modulating-valve, and outlet modulating-valve have a different cross section.
  • the modulating-valve has a smaller cross section than the purge-valve.
  • the modulating-valve facilitates a slow mass flow of gas into at least a segment of the gas flow mechanism.
  • purging is performed within at least one segment of the gas flow mechanism.
  • at least two segments of the gas flow mechanism are purged simultaneously.
  • at least two segments of the gas flow mechanism are purged sequentially.
  • purging is performed independently within one or more segments of the gas flow mechanism.
  • the one or more segments of the gas flow mechanism is isolated with respect to their gas flow.
  • purging is performed collectively within two or more segments of the gas flow mechanism.
  • purging is switched from being performed independently to being performed collectively, and vice-versa.
  • switching is based on a reactive agent level threshold.
  • purging includes engaging and/or disengaging an operation of a pump.
  • purging comprises separating at least one segment of the gas flow mechanism and purging it separately.
  • purging comprises fluidly separating at least one segment of the gas flow mechanism, and purging it separately.
  • purging separately excludes using a pump.
  • the material used during the 3D printing comprises an elemental metal, metal alloy, ceramic, an allotrope of elemental carbon, polymer, or a resin. In some embodiments, the material used during the 3D printing comprises an elemental metal, metal alloy, ceramic, or an allotrope of elemental carbon. In some embodiments, the material used during the 3D printing comprises a particulate material. In some embodiments, the material produced during the 3D printing comprises soot, and/or a transformed material. In some embodiments, the transformed material comprises a molten material (e.g., that subsequently solidified). In some embodiments, the gas flow mechanism comprises a processing chamber in which the 3D object is printed during the 3D printing.
  • a system used in 3D printing of at least one 3D object comprises: a gas flow mechanism, which gas flow mechanism comprises an opening; and at least one controller that is operatively coupled to the gas flow mechanism, which at least one controller is programmed to direct performance of the following operations during the 3D printing: operation (i) direct flowing at least one gas at a velocity through the gas flow mechanism, which at least one gas is inserted to the gas flow mechanism through the opening, which gas is inert with respect to the material used or produced in the 3D printing of the 3D object, operation (ii) direct maintaining a pressure of the at least one gas in the gas flow mechanism to above an ambient atmospheric pressure, and operation (iii) direct maintaining a low level of a reactive agent in the gas flow mechanism, which low level is below a violent reaction level of the reactive agent with the material used or produced during the 3D printing, wherein the material used or produced during the 3D printing reacts violently at an ambient atmosphere that flows at the velocity.
  • the opening is configured to facilitate transporting the at least one gas to or from the gas flow mechanism.
  • the system further comprises an energy source configured to generate an energy beam that transforms the material used in 3D printing for printing of the 3D object, and wherein the controller is operatively coupled to the energy beam and directs the energy beam to transform the material used in 3D printing for printing of the 3D object.
  • the violent reaction is an exothermic reaction.
  • the violent reaction comprises combustion, ignition, or flaming.
  • the gas flow mechanism comprises a channel, chamber, valve, or a pump.
  • the system further comprises one or more valves operatively coupled to the gas flow mechanism.
  • the one or more valves are configured to facilitate maintaining a low level of a reactive agent in the gas flow mechanism.
  • the at least one controller is operatively coupled to the one or more valves, and is further configured to direct performance of operation (iv) direct the at least one valve to open or close.
  • at least one controller is configured to direct the timing and/or degree at which the at least one valve opens or closes.
  • at least two of operations (i), (ii), (iii), and (iv) are directed by the same controller.
  • at least two of operations (i), (ii), (iii), and (iv) are directed by the different controllers.
  • the two or more of operation (i), (ii), and (iii) are directed by the same controller.
  • the at least one controller is a plurality of controllers.
  • two or more of operation (i), (ii), and (iii) are directed by different controllers.
  • the controller is operatively coupled to an energy beam and directs the energy beam to transform the material used in 3D printing for printing the 3D object.
  • the violent reaction is an exothermic reaction.
  • the violent reaction comprises combustion, ignition, or flaming.
  • the at least one controller is operatively coupled to one or more valves and is further configured to direct performance of operation (iv): direct the at least one valve to open or close.
  • the one or more valves is configured to facilitate maintaining a low level of a reactive agent in the gas flow mechanism.
  • the at least one controller is configured to direct the timing and/or degree at which the at least one valve opens or closes.
  • at least two of operations (i), (ii), (iii), and (iv) are directed by the same controller.
  • at least two of operations (i), (ii), (iii), and (iv) are directed by the different controllers.
  • a computer software product for 3D printing of at least one 3D object comprises a non-transitory computer-readable medium in which program instructions are stored, which instructions, when read by a computer, cause the computer to perform operations comprising: operation (i) direct flowing at least one gas at a velocity through a gas flow mechanism, which at least one gas is inserted to a gas flow mechanism through an opening in the gas flow mechanism, which gas is inert with respect to a material used or produced in a 3D printing of the 3D object; operation (ii) direct maintaining the pressure of the at least one gas in the gas flow mechanism to above an ambient atmospheric pressure; and operation (iii) direct maintaining a low level of a reactive agent in the gas flow mechanism, which low level is below a violent reaction level of the reactive agent with the material used or produced during the 3D printing, wherein the material used or produced during the 3D printing reacts violently at an ambient atmosphere flowing at the velocity.
  • isolating comprises reducing influx of the external atmosphere. In some embodiments, isolating comprises facilitating penetrationof the external atmosphere.
  • the first canister comprises a non-reactive, inert, and/or noble-gas interior atmosphere. In some embodiments, the non-reactivity is relative to a reaction with the material used or produced during the 3D printing.
  • the second canister comprises a non-reactive, inert, and/or noble-gas interior atmosphere. In some embodiments, non-reactive is relative to a reaction with the material used or produced during the 3D printing.
  • switching comprises determining clogging of the first filter. In some embodiments, switching comprises determining unsafe use of the first filter. In some embodiments, switching comprises determining presence and safe use of the second filter.
  • an apparatus for 3D printing of at least one 3D object comprises: a first canister comprising a first filter, which first filter is configured to separate gas-borne material from a recirculating gas at least during the 3D printing, which first canister comprises a first casing that separates the first filter from an external atmosphere comprising a reactive agent, wherein the gas-borne material comprises a material used or produced during the 3D printing; a second canister comprising a second filter, which second filter is configured to separate the gas-borne material from the recirculating gas which second canister comprises a second casing that separates the filter from the external atmosphere comprising the reactive agent; and a gas flow mechanism comprises the first canister, the second canister, or a processing chamber where the 3D object is printed during the 3D printing, which gas flow mechanism is configured to recirculate gas from the processing chamber to the first canister and/or to the second canister.
  • the first canister comprises a first casing configured to prevent combustion of the reactive agent with the gas-borne material.
  • the second canister comprises a second casing configured to prevent combustion of the reactive agent with the gas-borne material.
  • the first canister comprises a first casing that is configured to prevent combustion of the reactive agent with the gas-borne material
  • the second canister comprises a second casing configured to prevent combustion of the reactive agent with the gas-borne material
  • the first casing is of the same type as the second casing.
  • the first canister comprises a first casing that is configured to prevent combustion of the reactive agent with the gas-borne material
  • the second canister comprises a second casing configured to prevent combustion of the reactive agent with the gas-borne material
  • the first casing is different from the second casing.
  • the first casing is different from the second casing by its material type, casing wall structure, and/or casing shape.
  • the first casing and/or second casing comprises (i) a material type, (ii) casing wall structure, or (iii) casing shape, that is configured to reduce a flow of the external atmosphere into the first canister or second canister respectively.
  • the decoupling of the first canister and/or the second canister from the processing chamber is configured to facilitate recirculation of the gas at least in the processing chamber. In some embodiments, the decoupling of the first canister or the second canister from the processing chamber is configured to facilitate continuous filtering of the gas-borne material during the 3D printing.
  • the first canister comprises a first valve. In some embodiments, the first valve can couple the first canister to the processing chamber. In some embodiments, the second canister comprises a second valve. In some embodiments, the second valve couples the second canister to the processing chamber.
  • a system used in 3D printing of at least one 3D object comprises: a first canister comprising a first filter, wherein the first filter is configured to separate at least one gas from a gas-borne material that is used or generated during a 3D printing of the at least one 3D object, wherein the external atmosphere comprises a reactive agent that violently reacts with the gas-borne material, wherein the first canister is configured to separate the first filter from an external atmosphere, wherein the at least one gas does not react violently with the reactive agent; a second canister comprising a second filter, wherein the second filter is configured to separate the at least one gas from the gas-borne material, wherein the second canister is configured to separate the second filter from the external atmosphere to lower the possibility of violent reaction between the gas-borne material and the reactive agent; a gas flow mechanism comprising the first canister, or the second canister, which gas flow mechanism is configured to accommodate the at least one gas; and at least one controller that is operatively coupled to the first canister, and the second
  • an apparatus for 3D printing of at least one 3D object comprises at least one controller that is programmed to collectively or separately perform the following operations at least during the 3D printing: operation (i) direct using a first filter to separate a gas-borne material from at least one gas that recirculates through a gas flow mechanism, which first filter is housed in a first canister that is configured to separate the first filter from an external atmosphere, wherein the gas-borne material is used or produced during the 3D printing, which gas flow mechanism comprises the first canister, wherein the external atmosphere comprises a reactive agent that violently reacts with the gas-borne material, wherein the at least one gas does not react violently with the reactive agent; and operation (ii) direct switching from (a) using the first filter to separate the at least one gas from the gas- borne material to (b) using a second filter to separate the at least one gas from the gas- borne material, which switching facilitates continuous and uninterrupted separation of the gas-borne material from the at least one gas, wherein the second filter is
  • the gas flow mechanism comprises a processing chamber in which the 3D object is printed during the 3D printing.
  • the processing chamber is operatively coupled to first canister, the second canister, or both the first canister and the second canister.
  • the processing chamber is fluidly connected to first canister, the second canister, or both the first canister and the second canister.
  • the at least one controller is programmed to direct an energy beam to transform the material used for the 3D printing to transform to print the 3D object.
  • a system for printing a 3D object comprises: an energy source configured to generate an energy beam for transforming at least a portion of a pretransformed material to a transformed material; a platform configured to support the 3D object; and an enclosure configured to enclose at least a portion of the platform during a printing operation, the enclosure (I) is operatively coupled to, or comprises a gas inlet portion at a first enclosure side and (II) is operatively coupled to, or comprises a gas outlet portion at a second enclosure side, wherein the gas inlet portion is configured to direct a flow of gas over a target surface that is (i) adjacent to the platform or (ii) comprises an exposed surface of the platform, and to the gas outlet portion, which gas inlet portion is configured to alter at least one characteristic of the flow of gas.
  • altering the at least one characteristic of the flow of gas comprises altering a shape, a volume, a velocity, a direction, or an alignment of the flow of gas.
  • the platform is configured to vertically translate. In some embodiments, the platform is configured to vertically translate during the printing.
  • the target surface comprises the exposed surface of the 3D object.
  • the pre-transformed material is part of a material bed that is disposed on the platform. In some embodiments, the target surface comprises an exposed surface of the material bed.
  • the gas inlet portion is configured to direct the flow of gas in a direction that is substantially parallel to the target surface.
  • the system may be configured for printing a plurality of 3D objects. In some embodiments, the system may be configured for printing a plurality of 3D objects in the printing operation.
  • the first enclosure side faces the second enclosure side. In some embodiments, first enclosure side is disposed in an opposite direction to the second enclosure side.
  • the gas inlet portion is configured to direct the flow of gas in a first direction, wherein the gas inlet portion is configured to reduce a second flow of gas in a second direction that is substantially orthogonal to the first direction.
  • the enclosure comprises a window configured to allow the energy beam to pass therethrough. In some embodiments, the window is located vertically with respect to the platform. In some embodiments, the gas inlet portion is configured to direct the flow of gas in a substantially parallel to an average plane of the window.
  • the gas inlet portion comprises at least one baffle having at least one surface that is (e.g., substantially) non-parallel to the exposed surface of the platform.
  • the flow of gas over the target surface is substantially in accordance with a first directional component, wherein the at least one baffle is configured to increase a second directional component of the flow of gas within the gas inlet portion, wherein the second directional component is (e.g., substantially) non-parallel with the first directional component.
  • the enclosure is configured to hold a positive pressure.
  • the flow of gas over the target surface is substantially in an X direction.
  • the at least one baffle is configured to increase Z and/or Y directional components of the flow of gas through the gas inlet portion.
  • the gas inlet portion comprises an elongated opening defined by a width and height. In some embodiments, a width-to-height ratio of the elongated opening is at least about 1 , 1.5, 2, 5, 10, 15, 20, or 50.
  • the gas inlet portion comprises a first outlet port. In some embodiments, the first outlet port includes a perforated plate that channels the flow of gas through the first outlet port. In some embodiments, the gas inlet portion comprises a plurality of channels that channel the flow of gas through the first outlet port.
  • the plurality of channels are within a flow straightener (e.g., flow aligner).
  • the first outlet port includes a perforated plate that channels the flow of gas through the first outlet port.
  • the gas outlet portion has an aerodynamic shape configured to reduce gas turbulence within a processing chamber of the enclosure.
  • a path of the energy beam in a volume of a processing chamber of the enclosure defines a processing cone.
  • the gas outlet portion comprises a second inlet port and a second outlet port, wherein the gas outlet portion is configured to reduce backflow, turbulence, standing vortex, or any combination thereof, at least in the processing cone.
  • channeling the flow of gas comprises aligning the flow of gas.
  • the gas inlet portion is separated from a processing chamber of the enclosure by a first wall.
  • the gas outlet portion is separated from the processing chamber of the enclosure by a second wall.
  • the system comprises an optical mechanism that is configured to control a trajectory of the energy beam through the enclosure.
  • at least a portion of the optical mechanism is enclosed in a casing the casing is purged by a purging gas flow.
  • the casing is leaky (e.g., to facilitate exit of the flow of gas).
  • the energy source is a first energy source and the energy beam is a first energy beam.
  • away from the window comprises toward a processing chamber of the enclosure.
  • the outlet opening is arranged to direct the flow of gas in a direction substantially parallel to a surface of the window.
  • the system further comprises a gas recycling system comprising: a filtration system that filters debris from the flow of gas exiting the gas outlet portion.
  • the system further comprises a gas recycling system comprising: at least one pump configured to control a pressure of the flow of gas.
  • controlling the pressure comprises regulating the pressure.
  • controlling the pressure comprises increasing the pressure.
  • the system comprises a window housing having a window and an outlet opening, wherein the gas recycling system is configured to supply clean gas to the outlet opening.
  • the gas inlet portion is configured to direct the flow of gas toward a surface of a material bed of the pretransformed material.
  • the gas inlet portion comprises a backflow gas outlet portion configured to allow a backflow of gas to exit the enclosure.
  • the backflow gas outlet portion is disposed proximate to a gas inlet port of the gas inlet portion.
  • a method for printing a 3D object comprises: (a) directing a flow of gas through an enclosure from an inlet portion to an outlet portion, which flow of gas is above a target surface; (b) altering at least one characteristic of the flow of gas as it flows through the inlet portion; and (c) directing an energy beam toward a platform to transform a pre-transformed material to a transformed material as part of the printing of the 3D object, wherein the platform is disposed in the enclosure.
  • the flow of gas above the target surface is in accordance with a first directional component, the method further comprising increasing a second directional component of the flow of gas within the inlet portion, the second directional component being (e.g., substantially) non-parallel with respect to the first directional component.
  • the flow of gas above the target surface is in accordance with a first directional component, the method further comprising increasing the flow of gas in the first directional component by directing the flow of gas through a plurality of channels within the inlet portion.
  • one or more controllers collectively or separately are programed to direct the operations of (a), (b) and (c).
  • an insubstantial amount of debris affects the printing of the three-dimensional3D object. In some embodiments, insubstantial comprises negligent, non-material, inconsequential, trivial, or negligible. In some embodiments, insubstantial is to a detectable degree. In some embodiments, during operation (c) an insubstantial amount of debris interacts with the energy beam. In some embodiments, during operation (c) an insubstantial amount of debris accumulates on and/or obstructs a window through which the energy beam travels. In some embodiments, the flow of gas is a primary flow of gas.
  • the method further comprises directing a secondary flow of gas within a volume of a recessed portion that is configured to support the window.
  • altering the at least one characteristic of the flow of gas comprises altering a shape, a volume, a velocity, a direction, or an alignment of the flow of gas.
  • vertically translating the platform is during the printing.
  • the target surface is an exposed surface of the 3D object.
  • the pretransformed material is part of a material bed that is disposed on the platform.
  • the target surface comprises an exposed surface of the material bed.
  • the method further comprises printing a plurality of 3D objects.
  • directing the flow of gas over the target surface is while at least the portion of the pre-transformed material is being transformed to the transformed material.
  • the inlet portion directs the flow of gas in a direction that is substantially parallel to the target surface.
  • the inlet portion directs the flow of gas in a first direction and alters at least one characteristic of the flow of gas in a second direction.
  • the second direction is substantially orthogonal to the first direction.
  • directing the energy beam at the target surface comprises directing the energy beam through a window that is located (I) vertically with respect to the platform and/or (II) in a wall of the enclosure that faces the platform.
  • the flow of gas over the target surface is substantially in an X direction.
  • the inlet portion comprises baffles that increase Z and/or Y directional components of the flow of gas through the inlet portion.
  • the inlet portion comprises an elongated opening defined by a width and height, wherein a width-to- height ratio of the elongated opening is at least about 1 , 1.5, 2, 5, 10, 15, 20, or 50.
  • the inlet portion comprises an outlet port comprising a plurality of channels that aligns the flow of gas through the outlet port.
  • the outlet port comprises a perforated plate.
  • the inlet portion is separated from a processing chamber of the enclosure by a first wall.
  • the enclosure comprises a processing chamber. In some embodiments, the method further comprising directing the flow of gas into the processing chamber via the inlet portion that is (i) a part of the processing chamber or (ii) is operatively coupled to the processing chamber. In some embodiments, the method further comprising directing the flow of gas out of the processing chamber via a gas outlet portion that is (i) a part of the processing chamber or (ii) is operatively coupled to the processing chamber. In some embodiments, the gas outlet portion has an aerodynamic shape that reduces a turbulence of the flow of gas within the processing chamber. In some embodiments, directing the energy beam at the target surface comprises controlling a trajectory of the energy beam through the enclosure using an optical mechanism.
  • the method further comprises purging a casing with a purging gas flow. In some embodiments, at least a portion of the optical mechanism is enclosed by the casing. In some embodiments, the casing is leaky (e.g., to facilitate exit of the purging gas flow from the casing).
  • the energy beam is a first energy beam. In some embodiments, the method further comprises directing a second energy beam toward the platform. In some embodiments, the second energy beam has a different energy characteristic than the first energy beam. In some embodiments, directing the energy beam at the target surface comprises directing the energy beam through a window positioned within a recessed portion that supports the of the enclosure.
  • the method further comprises directing a purging flow of gas to a volume of the recessed portion. In some embodiments, the purging flow of gas is in a direction away from a surface of the window. In some embodiments, the purging flow of gas is in a direction substantially parallel to a surface of the window. In some embodiments, the method further comprises directing the flow of gas out of the enclosure and through a gas recycling system. In some embodiments, the gas recycling system comprises: (a) a filtration system that filters debris from the flow of gas exiting the enclosure, or (b) at least one pump configured to increase a pressure of the flow of gas. In some embodiments, the method further comprises supplying clean gas to an outlet opening of a window housing.
  • the window housing is coupled to the window.
  • the inlet portion is configured to direct the flow of gas toward the target surface.
  • the method further comprises backflowing a portion of the flow of gas from the enclosure through a back-flow outlet port that is proximal to an outlet port of a gas inlet portion.
  • the flow of gas in the enclosure facilitates a reduced amount of debris from interfering with the printing of the 3D object.
  • the reduced amount of debris corresponds to an amount that is not material to formation of the 3D object.
  • a path of the energy beam in a volume of a processing chamber of the enclosure defines a processing cone, wherein the reduced amount of debris is at least in the processing cone.
  • a system for printing a 3D object comprises: an energy source configured to generate an energy beam for transforming a pre-transformed material to a transformed material; a platform configured to support the 3D object; and an enclosure configured to enclose the platform, the enclosure comprising: a window configured to allow the energy beam to pass therethrough, and (i) a recessed portion that supports the window and that includes a wall that defines a volume, (ii) an outlet opening configured to direct a flow of gas into the volume in a direction away from the window, or (iii) a combination of (i) and (ii).
  • the window has an internal window surface that is exposed to the volume. In some embodiments, the direction away from the window is at an acute angle with respect to the internal window surface. In some embodiments, the window has a plurality of outlet openings. In some embodiments, at least two of the outlet openings face each other. In some embodiments, at least a first opening and a second opening of the plurality of outlet openings are configured such that: (a) the first opening directs a first gas flow away from the window and towards the second opening, and (b) the second opening directs a second gas flow away from the window and towards the first opening. In some embodiments, the second gas flow merges with the first gas flow to form a third gas flow.
  • the first opening and the second opening are configured to facilitate flowing the third gas flow towards a plane of a target surface that is disposed in the enclosure.
  • the window has an internal window surface that is exposed to the volume.
  • a flow vector of the flow of gas is non- tangential to the internal window surface.
  • the flow of gas is characterized as having cone-shaped convergence vectors.
  • the enclosure includes a window housing that supports the window and at least partially defines the recessed portion.
  • the window housing includes a plenum portion that is configured to supply gas to the outlet opening.
  • the outlet opening is within the wall.
  • the system comprises a plurality of windows that are configured to allow the energy beam to pass therethrough.
  • the system comprises a plurality of window housings that are configured to support the plurality of windows.
  • the volume is between the window and the platform.
  • the recessed portion and/or an outlet opening within the wall is/are configured to reduce an amount of debris from (i) altering the energy beam, (ii) obstructing the window, or (iii) any combination thereof.
  • altering the energy beam comprises altering a wavelength, power density, or trajectory thereof.
  • obstructing the window comprises adhering to and/or reacting with the optical window.
  • a method for printing a 3D object comprises: (a) directing an energy beam toward a platform to transform at least a portion of a pre-transformed material to a transformed material, wherein the platform is disposed in an enclosure, wherein the energy beam is directed through a window that is (i) positioned within a recessed portion of the enclosure, the recessed portion including a wall that defines a volume, (ii) proximate to an outlet opening configured to allow a flow of gas to flow therethrough, or (iii) a combination of (i) and (ii); and (b) in case of (ii) or (iii), directing the flow of gas through the outlet opening in a direction away from the window.
  • one or more controllers are collectively or separately programed to direct operations (a) and (b).
  • an insubstantial amount of debris affects the printing of the 3D object.
  • insubstantial comprises negligent, non-material, inconsequential, trivial, or negligible.
  • insubstantial is to a detectable degree.
  • an insubstantial amount of debris interacts with the energy beam.
  • an insubstantial amount of debris accumulates on and/or obstructs the window.
  • directing the flow of gas through the outlet opening in the direction away from the window further comprises directing the flow of gas into the volume of the recessed portion.
  • the window has an internal window surface that is exposed to the volume.
  • the direction away from the window is at an acute angle with respect to the internal window surface.
  • the window has an internal window surface that is exposed to the volume.
  • directing the flow of gas in operation (b) comprises directing a flow vector of the flow of gas in a direction non-tangential to the internal window surface.
  • directing the flow of gas in operation (b) comprises directing the flow of gas in convergence vectors. In some embodiments, the convergence vectors have a triangular shape.
  • the enclosure includes a window housing that supports the window and at least partially defines the recessed portion.
  • the window housing includes a plenum portion that supplies gas to the outlet opening.
  • the method further comprises flowing the gas through the plenum portion.
  • the energy beam is a first energy beam and the window is a first window.
  • the method further comprising directing a second energy beam toward the platform through a second window.
  • the second window is positioned in a second recessed portion of the enclosure.
  • the volume is between the window and the platform.
  • a system for printing a three-dimensional (3D) object comprises: a platform configured to support the 3D object; and an enclosure configured to enclose at least the platform during a printing operation, the enclosure operatively coupled to, or comprises: a gas inlet portion at a first enclosure side, the gas inlet portion configured to direct a flow of gas in a first direction over a target surface that is (i) adjacent to the platform, or (ii) comprises a surface of the platform, and a gas outlet portion at a second enclosure side, the gas outlet portion configured to direct the flow of gas out of the enclosure via at least one outlet opening, wherein (a) the gas inlet portion includes at least one baffle configured to direct gas in a second direction different from the first direction, which gas is directed within the gas inlet portion, (b) the gas outlet portion has a cross-sectional shape that tapers toward the at least one outlet opening, or (c) any combination of (a) and (b).
  • the wall comprises one or more openings configured to allow the flow of gas to enter the gas outlet portion from the main portion of the enclosure. In some embodiments, a size of the one or more openings is adjustable.
  • the gas inlet portion comprises a flow aligning structure (e.g., comprises the at least flow aligner) configured to align the flow of gas in the first direction by directing the flow of gas through a plurality of channels.
  • the flow aligning structure is positioned at a part of the gas inlet portion adjacent the platform. In some embodiments, the flow aligning structure is positioned at a bottom part of the gas inlet portion. In some embodiments, the flow aligning structure has a height of at most about 5, 4, 3, 2, 1 , or 0.5 inches.
  • a method for printing a 3D object comprises: (a) directing a flow of gas through an enclosure from a gas inlet portion to a gas outlet portion, which flow of gas is in a first direction over a target surface that is (i) adjacent to a platform configured to support the 3D object, or (ii) comprises a surface of the platform; and (b) using at least one baffle of the gas inlet portion to direct the flow of gas in a second direction different from the first direction as it flows through the gas inlet portion, (b) tapering the flow of gas within the gas outlet portion toward at least one outlet opening of the gas outlet portion, or (c) a combination of (a) and (b).
  • the second direction is substantially non-parallel to the first direction. In some embodiments, the second direction is substantially orthogonal to the first direction. In some embodiments, the first direction is substantially parallel to the surface of the platform. In some embodiments, the method further comprises aligning the flow of gas in the first direction by directing the flow of gas through a plurality of channels within the gas inlet portion. In some embodiments, the method further comprises directing an energy beam toward the platform to transform a pre-transformed material to a transformed material as part of the printing of the 3D object. In some embodiments, the method further comprises causing the flow of gas to flow through at least one filter (e.g., HEPA filter) prior to entering the gas inlet portion.
  • at least one filter e.g., HEPA filter
  • an apparatus for printing a 3D object comprises: a platform configured to support the 3D object during the printing; an energy source configured to generate an energy beam that transforms a pre-transformed material to a transformed material to print the 3D object, which energy beam is operatively coupled to the platform; a window that facilitates transmittal of the energy beam therethrough; and a wall configured to at least in part support the window and define a volume adjacent to the window, which wall comprises (i) a channel configured to facilitate flow of a gas therethrough, and (ii) an opening of the channel configured to direct flow of the gas away from the window, which opening is disposed adjacent to the window.
  • the window is an optical window.
  • the platform is housed in an enclosure that comprises an outlet opening configured to direct a flow of gas into the volume in the direction away from the window.
  • the platform is housed in an enclosure that comprises the volume, the wall, and the window.
  • the window comprises an internal window surface that is exposed to the volume.
  • the direction away from the window is at an acute angle with respect to the internal window surface.
  • the wall comprises a plurality of (outlet) openings. In some embodiments, at least two of the (outlet) openings face each other. In some embodiments, the opening corresponds to an annular-shaped slit.
  • a flow vector of the flow of the gas is non-tangential to the internal window surface.
  • the outlet is configured to facilitate a flow of gas away from the window that is characterized as having cone-shaped convergence vectors.
  • the apparatus further comprises a holder configured to support the window.
  • the holder is operatively coupled to the wall and to the window.
  • the apparatus is configured to facilitate reduction in an amount of a debris formed during the printing from (i) altering the energy beam, (ii) obstructing the window, or (iii) a combination of (i) and (ii).
  • altering the energy beam comprises altering a wavelength, power density, or trajectory thereof.
  • obstructing the window comprises adhering to and/or reacting with the window.
  • the window comprises a material having a thermally conductivity higher than that of fused silica. In some embodiments, the material is substantially transparent to at least a portion of wavelengths of the energy beam.
  • the window comprises sapphire, crystal quartz, zinc selenide (ZnSe), magnesium fluoride (MgF 2 ), or calcium fluoride (CaF 2 ).
  • the window comprises a material having a thermal conductivity of at least about 5 W/m°C at 300 K.
  • the enclosure is configured to maintain an internal atmosphere at a positive pressure.
  • the energy source is configured to direct the energy beam through another volume defined by a processing cone within the enclosure.
  • the enclosure comprises at least one vacuum duct that is configured to remove at least a portion of debris within the processing cone.
  • the channel comprises a portion that is different from a horizontal channel.
  • the channel comprises a vertical channel portion.
  • the channel is a covered channel.
  • the opening forms an acute angle with the (e.g., optical) window. In some embodiments, the acute angle points the opening towards the platform.
  • the flow of the gas is filtered by a HEPA filter prior to its entry into the channel.
  • a method for printing a 3D object comprises: (a) directing an energy beam through a window toward a platform to transform at least a portion of a pre-transformed material to a transformed material to form the 3D object; and (b) directing a flow of a gas in a direction away from the window, which gas flows through a channel in a wall and through an outlet opening in the wall, which wall at least in part supports the window, which outlet opening is adjacent to the window, which outlet opening is coupled to the channel.
  • one or more controllers collectively or separately are programed to direct the operations of (a) and (b).
  • a reduced amount of debris affects the printing of the 3D object.
  • reduced is in comparison to lack of the flow of the gas.
  • an insubstantial amount of debris affects the printing of the 3D object.
  • insubstantial comprises negligent, non-material, inconsequential, trivial, or negligible.
  • insubstantial is to a detectable degree.
  • an insubstantial amount of debris interacts with the energy beam.
  • an insubstantial amount of debris accumulates on and/or obstructs the window.
  • a substantially undetectable amount of debris affects a peak intensity of the energy beam used to transform the pre-transformed material.
  • a peak intensity of the energy beam is substantially unchanged after transformation of at least 500 layers of pre-transformed material.
  • a peak intensity of the energy beam is substantially unchanged after transformation of at least about 3.4 milliliters of pre-transformed material.
  • directing the flow of the gas through the outlet opening in the direction away from the window further comprises directing the flow of the gas into a volume of a recessed portion defined at least in part by the wall and the window.
  • the window has an internal window surface that is exposed to the volume.
  • a direction away from the window is at an acute angle with respect to the internal window surface.
  • the window has an internal window surface that is exposed to the volume.
  • directing the flow of the gas in operation (b) comprises directing a flow vector of the flow of gas in a direction non-tangential to the internal window surface.
  • directing the flow of the gas in operation (b) comprises directing the flow of gas in convergence vectors.
  • the convergence vectors have a triangular shape.
  • the flow of the gas flows away from the window comprises a pyramidal, conical, and/or spiraling shape in a recessed portion defined at least in part by the wall and the window.
  • the platform is disposed in an enclosure that includes a window housing that supports the window and at least partially defines the recessed portion.
  • the window housing includes a plenum portion that supplies gas to the outlet opening, and wherein the method further comprises flowing the gas through the plenum portion.
  • the window housing comprises the wall.
  • the energy beam is a first energy beam and the window is a first window
  • the method further comprises directing a second energy beam toward the platform through a second window.
  • the platform is disposed in an enclosure that includes the window that is part of a first recessed portion.
  • the second window is positioned in a second recessed portion of the enclosure.
  • the volume is between the window and the platform.
  • a system for printing a 3D object comprises: a platform configured to support the 3D object (e.g., during the printing); a material dispenser configured to dispense a pre-transformed material towards the platform, wherein the material dispenser is configured to traverse in a first direction adjacent to the platform; and a gas flow director configured to direct a flow of gas in a second direction adjacent the platform, wherein the first direction is non-parallel to the second direction.
  • the gas flow director comprises a gas inlet portion comprises at least one baffle configured to change a direction of the flow of gas, uniformity along a (e.g., vertical) cross section of the flow of gas, and/or a size of a (e.g., vertical) cross section of the flow of gas, in the gas inlet portion.
  • change comprises adjust temperature, adjust chemical makeup (e.g., level of a reactive agent, e.g., oxygen or humidity), homogenize or expand, the flow of gas.
  • the layer forming apparatus comprises a leveler having an elongated edge that is configured to level an exposed surface of a material bed. In some embodiments, the layer forming apparatus comprises a material remover having an elongated opening that is configured to accept at least a portion of material from a material bed therethrough. In some embodiments, the system further comprises at least one controller configured to cause the layer forming apparatus to form the at least one layer of pre-transformed material (e.g., while the gas flow director directs the flow of gas in the second direction). In some embodiments, the system further comprises at least one controller configured to cause the layer forming apparatus to form the at least one layer of pre-transformed material (e.g., while the gas flow director is directing the flow of gas in the second direction).
  • the system further comprises at least one controller configured to cause the gas flow director to direct the flow of gas out of the enclosure (e.g., and away from the platform), e.g., while the layer forming apparatus forms the at least one layer of pre-transformed material.
  • the system further comprises at least one controller configured to cause the flow of gas director to direct the flow of gas out of an enclosure while the material dispenser dispenses the pre-transformed material.
  • the enclosure comprises: the platform, at least part of the flow of gas, and the material dispenser.
  • away from the platform comprises outside of an enclosure configured to enclose the at least one layer of pretransformed material during a printing operation.
  • using the gas flow director to direct a flow of gas in a second direction is when transforming the pre-transformed material to a transformed material as part of the 3D object.
  • the method further comprises controlling one or more characteristics of the flow of gas.
  • one or more characteristics of the flow of gas differs (i) when transforming the pre-transformed material to a transformed material as part of the 3D object as compared to a period lacking the transforming, and/or (ii) while using the material dispenser as compared to during a period where the material dispenser is not used to dispense the pre-transformed material.
  • the method further comprises modifying at least one of a shape, a velocity, a chemical makeup (e.g., level of a reactive agent), a temperature, or a uniformity of the flow of by flowing the flow of gas through a gas inlet portion that is coupled to or is a part of an enclosure that comprises the platform, at least part of the flow of gas, and the material dispenser.
  • the reactive agent reacts with a by-product of the printing and/or the pre-transformed material under the printing, flow of gas, and/or gas filtration conditions.
  • the method further comprises directing the flow of gas through a gas outlet portion subsequent to directing the flow of gas adjacent to the platform.
  • the method further comprises directing an energy beam toward the platform to transform at least a portion of the at least one layer of pre-transformed material to a transformed material.
  • the method further comprises translating the platform.
  • the platform is translated in a third direction that is different than at least one of the first and second directions.
  • the third direction is substantially orthogonal to at least one of the first and second directions.
  • a system for printing a 3D object comprises: a platform configured to support at least one layer of pre-transformed material; a layer forming apparatus configured to traverse adjacent the platform and dispense a pre-transformed material towards the platform; and a gas flow director configured to direct a flow of gas at a velocity adjacent the platform, wherein the gas flow director is configured to alter the velocity for at least a portion time that the layer forming apparatus traverses adjacent the platform.
  • the layer forming apparatus is configured to dispense a planar layer of the pre-transformed material.
  • the pre-transformed material forms a material bed, and wherein the platform is configured to support the material bed.
  • the system further comprises an energy source configured to generate an energy beam that transforms the pre-transformed material to a transformed material as part of the 3D object.
  • alter the velocity comprises increase or decrease the velocity.
  • alter comprises linear alteration of the velocity.
  • the gas flow director is configured to change the flow of gas when the layer forming apparatus is dispensing the pre-transformed material.
  • the gas flow director is configured to change the flow of gas when the layer forming apparatus is dispensing the pre-transformed material.
  • the layer forming apparatus comprises at least one of (i) a material dispenser configured to dispense the at least one layer of pre-transformed material, (ii) a material remover configured to remove at least a portion of the at least one layer of pre-transformed material, or (iii) leveler configured to level an exposed surface of the at least one layer of pretransformed material.
  • the material dispenser and the material remover traverse together over the platform.
  • the material dispenser is configured to dispense the at least one layer of pre-transformed material when traversing in a forward direction over the platform.
  • the material remover is configured to remove the at least a portion of the at least one layer of pre-transformed material when traversing in a reverse direction over the platform.
  • the gas flow director comprises at least one valve. In some embodiments, the at least one valve (a) constricts the flow of gas, (b) obstructs the flow of gas, (c) diverts the flow of gas, or (d) at least two of (a), (b) or (c).
  • the gas flow director is configured to divert at least a portion of the flow of gas to a gas outlet. In some embodiments, the gas flow director is configured to divert at least a portion of the flow of gas to a recycling system.
  • a method of printing a 3D object comprises: (A) traversing a layer forming apparatus adjacent a platform to dispense a pre-transformed material towards the platform; and (B) causing a gas flow director to direct a flow of gas adjacent the platform, wherein the gas flow director directs the flow of gas at a first velocity for at least a portion time that the layer forming apparatus is traversing adjacent the platform and at a second velocity for at least a portion of time that the layer forming apparatus is not traversing adjacent the platform.
  • the first velocity is greater than the second velocity. In some embodiments, the first velocity is less than the second velocity. In some embodiments, the gas flow director changes the flow of gas between the first velocity and the second velocity by diverting at least a portion of the flow of gas to a region within an enclosure that encloses the pre-transformed material. In some embodiments, the diverting is during the printing. In some embodiments, diverting the at least the portion of the flow of gas is toward a gas outlet. In some embodiments, the gas flow director changes the flow of gas between the first velocity and the second velocity by adjusting at least one pump that at least partially supplies and/or pressurizes the flow of gas.
  • the gas flow director changes the flow of gas between the first velocity and the second velocity by using at least one valve to (a) constrict the flow of gas, (b) obstruct the flow of gas, (c) divert the flow of gas, or (d) at least two of (a), (b) or (c).
  • the gas flow director changes the flow of gas between the first velocity and the second velocity during the printing.
  • the method further comprises directing an energy beam toward the platform to transform the pre-transformed material to a transformed material to print the 3D object.
  • the gas flow director changes the flow of gas between the first velocity and the second velocity during transformation of the pre-transformed material to a transformed material.
  • the method further comprises translating the platform. In some embodiments, the method further comprises translating the platform during the printing.
  • a system for printing a 3D object comprises: a platform configured to support the 3D object during the printing; an enclosure configured to enclose the 3D object within an internal atmosphere comprises a gas (e.g., during printing); and a filtering system configured to filter a gas-borne material from a flow of the gas that exits the enclosure, the filtering system comprises: a first canister operationally coupled with the enclosure and comprises a first filter, a second canister operationally coupled with the enclosure and comprises a second filter, wherein each of the first and second filters is configured to separate the gas-borne material from the flow of the gas, and at least one valve configured to switch a direction of the flow of the gas between the first canister and the second canister, which switching facilitates uninterrupted separation of the gas-borne material from the flow of the gas during the printing.
  • a first canister operationally coupled with the enclosure and comprises a first filter
  • a second canister operationally coupled with the enclosure and comprises a second filter
  • each of the first and second filters is configured to separate the gas-borne
  • each of the first and second filters is configured to (i) separate the gas-borne material from the flow of the gas. In some embodiments, each of the first and second filters is further configured to (i) separate the gas- borne material from an external atmosphere, and/or (ii) separate the flow of the gas from the external atmosphere. In some embodiments, during the printing, each of the first and second filters is further configured to (i) separate the gas-borne material from an external atmosphere, and/or (ii) separate the flow of the gas from the external atmosphere. In some embodiments, the system further comprises at least one pump configured to supply a pumping force that drives the flow of the gas through at least one of the first canister or the second canister and back into the enclosure.
  • the at least one pump is configured to direct the flow of the gas from an outlet port of the enclosure to an inlet port of the enclosure.
  • the first and second canisters are configured to substantially prevent a reactive agent in an external atmosphere from reacting with the gas- borne material within the first and second canisters respectively.
  • the first canister is fluidly coupled with the second canister.
  • fluidly coupled comprises facilitating travel of the gas and/or the gas borne material.
  • the first canister is fluidly coupled with the enclosure.
  • the second canister is fluidly coupled with the enclosure.
  • the platform is configured to traverse during printing. In some embodiments, the platform is configured to vertically traverse.
  • the enclosure is configured to maintain the internal atmosphere at a positive pressure.
  • the system further comprises a third filter coupled with a wall of the enclosure.
  • the third filter is within or proximate to a gas inlet portion and/or a gas outlet portion of the enclosure.
  • the first filter and/or the second filter comprises a HEPA filter.
  • the first canister comprises a first casing material and the second canister comprises a second casing material.
  • the first casing material has a different (i) material type, (ii) casing wall structure, (iii) casing shape, or (iv) at least two of (i) to (iii) compared to the second casing material.
  • the first canister comprises a first casing material and the second canister comprises a second casing material.
  • the first casing material has the same (i) material type, (ii) casing wall structure, (iii) casing shape, or (iv) at least two of (i) to (iii) as the second casing material.
  • the first canister comprises a first casing material and the second canister comprises a second casing material.
  • at least one of the first and/or the second casing materials includes one or more layers.
  • the one or more layers comprise a solid layer, a liquid layer, a semi-solid layer, or a gas-layer.
  • the first canister comprises a first valve. In some embodiments, the first valve operatively couples the first canister to the enclosure. In some embodiments, the second canister comprises a second valve. In some embodiments, the second valve operatively couples the second canister to the enclosure. In some embodiments, the at least one valve is configured to reversibly decouple the first canister and/or the second canister from the enclosure. In some embodiments, the gas-borne material comprises at least one of debris, soot, or pre-transformed material. In some embodiments, the system further comprises at least one sensor configured to detect (i) a reactive agent, or (ii) the gas-borne material in the flow of gas.
  • the reactive agent is reactive with the gas borne material under the conditions prevailing in the enclosure, first canister, and/or second canister.
  • the reactive agent comprises oxygen or water.
  • the system further comprises at least one sensor configured to detect (i) a presence or absence of the first filter and/or the second filter, (ii) a reactive species of the gas, (iii) a velocity of the gas traveling, or (iv) a pressure, in the first canister and/or the second canister. In some embodiments, detect is (i) during the printing, and/or (ii) a filtration process in the first canister and/or the second canister.
  • the method further comprises facilitating insertion of the filtered gas into the enclosure.
  • the method further comprises maintaining the flow of gas at or below (e.g., a pre-determined) velocity, temperature, and/or pressure associated with a risk of a violent reaction between the gas-borne material and a reactive agent (e.g., from an external atmosphere).
  • the method further comprises causing at least one pump to drive the flow of gas through the first canister gas and/or second canister.
  • the method further comprises printing the 3D object.
  • the gas-borne material is generated during the printing.
  • directing the gas flow from the first canister to a second canister comprises using at least one valve to switch a direction of the flow of gas from the first canister to the second canister. In some embodiments, using the at least one valve comprises altering a status of the at least one valve. In some embodiments, using the at least one valve comprises operationally decoupling the first canister or the second canister from the enclosure. In some embodiments, directing the flow of gas from the first canister to a second canister comprises altering a status of a first valve associated with the first canister and altering a status of a second valve associated with the second canister.
  • the method further comprises detecting (i) a presence or absence of the first filter and/or second filters, (ii) a reactive species in the flow of gas, (iii) a velocity of the flow of the gas, or (iv) a pressure, or (v) a temperature of the flow of gas, in the first canister and/or second canister. In some embodiments, detecting is (i) during the printing, and/or (ii) a filtration process in the first canister and/or second canister.
  • the method further comprises using at least one controller to (i) control the flow of gas, (ii) direct replacement of the first filter and/or second filter, and/or (iii) direct decoupling of the first canister and/or second canister from the enclosure (e.g., considering an output from the sensor).
  • the purging system is configured to direct the flow of gas away from the window.
  • the purging system comprises one or more channels.
  • the second wall comprises the one or more channels.
  • the system further comprises a plurality of windows that include the window.
  • the plurality of windows are arranged in a non-parallel alignment with a direction of a flow of gas above the platform.
  • the second wall comprises sides that at least partially enclose a volume of the recessed portion.
  • the system comprises at plurality of recessed portions.
  • the system comprises a plurality of energy sources.
  • the volume is between the window and the platform.
  • the window comprises a material having a thermally conductivity higher than that of fused silica. In some embodiments, the material is substantially transparent to at least a portion of wavelengths of the energy beam. In some embodiments, the window comprises at least one of sapphire, crystal quartz, zinc selenide (ZnSe), magnesium fluoride (MgF2), or calcium fluoride (CaF2). In some embodiments, window comprises a material having a thermal conductivity measurement of at least 5 (Watts per meter per degrees Celsius) W/m°C at 300 Kelvin (K). In some embodiments, the energy source is configured to direct the energy beam defined by a processing cone within the enclosure.
  • the enclosure comprises at least one vacuum duct that is configured to remove at least a portion of debris within and/or outside of the processing cone.
  • the recessed portion comprises one or more sensors configured to detect one or more input parameters within the enclosure during the printing.
  • the system further comprises at least one sensor configured to detect the gas-borne material.
  • the at least one sensors is operatively coupled to the window and/or the recessed portion.
  • the enclosure is configured to maintain an internal atmosphere at a positive pressure.
  • the first wall is a ceiling.
  • the gas-borne material comprises (i) a portion of the pretransformed material or (ii) debris associated with the transforming the pre-transformed material to the transformed material.
  • the method further comprises at least partially shielding the interior surface of the window from a gas-borne material.
  • the interior surface partially defines of an interior volume of the enclosure.
  • the gas borne material is produced during the printing.
  • the at least partially shielding comprises passively shielding.
  • passively shielding is accomplished by the geometry of the recessed portion.
  • the at least partially shielding comprises actively shielding.
  • actively shielding comprises flowing a gas through one or more channels in the second wall.
  • flowing the gas is to a direction away from the window. In some embodiments, the flowing of the gas results in an undetectable amount of debris affecting a peak intensity of the energy beam used to transform the pre-transformed material. In some embodiments, the flowing of the gas results in a peak intensity of the energy beam being substantially unchanged after transformation of at least 500 layers of pre-transformed material. In some embodiments, the flowing of the gas results in a peak intensity of the energy beam is substantially unchanged after transformation of at least about 3.4 milliliters of pre-transformed material.
  • a system for printing a three-dimensional object comprises: an enclosure configured to enclose the three-dimensional object during the printing, the enclosure comprising: a processing chamber having a gas outlet portion configured to direct flow of gas out of the enclosure via at least one outlet opening; and a window holder configured to support an optical window and having a wall defining a cavity disposed between the optical window and the processing chamber, the wall including a gas outlet having irregular perforations configured to direct a flow of gas into the cavity.
  • the flow of gas is a first flow of gas
  • the method further comprises directing a second flow of gas through the enclosure from a gas inlet portion of the enclosure to a gas outlet portion of the enclosure.
  • the method further comprises directing the first flow of gas to exit the enclosure through the gas outlet portion.
  • the flow of gas is a first flow of gas that flows along a first path in the enclosure, and wherein the method further comprises directing a second flow of gas through the enclosure along a second path, different from the first path, over a target surface that is (i) adjacent to a platform configured to support the three-dimensional object, or (ii) comprises a surface of the platform.
  • a portion of the first path is perpendicular to a portion of the second path.
  • the method further comprises opening a valve to direct the flow of the gas.
  • the method further comprises adjusting the valve to regulate a velocity of gas flow.
  • the method further comprises regulating a velocity of gas flow.
  • the method further comprises operating a pump and/or a gas cylinder to flow the gas.
  • the pump is a compressor.
  • the window holder comprises a foam having the plurality of irregular perforations.
  • the foam comprises an elemental metal, metal alloy, ceramic, or an allotrope of elemental carbon.
  • the window holder comprises, or is operatively coupled to, the foam having irregular perforations.
  • the foam is attached to the window holder.
  • the method further comprises generating the irregular perforations by a three-dimensional printing process.
  • the method further comprises generating the window holder by a three- dimensional printing process.
  • the method further comprises generating the irregular perforations by a three-dimensional printing process.
  • the enclosure is included in a printer that performs the printing of the three- dimensional object.
  • the flow of gas is a first flow of gas
  • the at least one controller is configured to direct a second flow of gas through the enclosure from a gas inlet portion of the enclosure to a gas outlet portion of the enclosure.
  • the at least one controller is configured to direct the first flow of gas to exit the enclosure through the gas outlet portion.
  • the flow of gas is a first flow of gas that flows along a first path in the enclosure, and wherein the at least one controller is configured to direct a second flow of gas through the enclosure along a second path, different from the first path, over a target surface that is (i) adjacent to a platform configured to support the three-dimensional object, or (ii) comprises a surface of the platform.
  • a portion of the first path is perpendicular to a portion of the second path.
  • the at least one controller is configured to direct a second flow of gas through the enclosure from a gas inlet portion to a gas outlet portion, the second flow of gas flowing along a first path over a target surface that is (i) adjacent to a platform configured to support the three-dimensional object, or (ii) comprises a surface of the platform; and wherein the at least one controller is configured to operatively couple to a valve configured to flow the gas, and wherein the at least one controller is configured to direct the valve to adjust the flow of the gas.
  • the at least one processor is configured to operatively couple to (i) a pump, (ii) a gas cylinder, or (iii) a pump and a gas cylinder, and wherein operations comprise directing the pump and/or the gas cylinder to facilitate the flow of the gas.
  • the pump is a compressor.
  • the gas cylinder is operatively coupled to a valve, wherein the at least one processor is configured to operatively couple to the valve, and wherein the operations comprise directing the gas cylinder to facilitate the flow of the gas at least in part by directing the valve.
  • the window holder comprises a foam having the irregular perforations.
  • a method of three-dimensional printing comprising: providing the device in any of the above devices; and using the device during the three- dimensional printing to print one or more three-dimensional object in a printing cycle.
  • an apparatus for three-dimensional printing comprises: at least one controller configured to (a) operatively couple to at least one component of a three-dimensional printing system, (b) direct the at least one guidance system using the device during the three-dimensional printing to print one or more three- dimensional objects in a printing cycle at least in part by using the device in any of the above devices.
  • the at least one component comprises an energy source configured to generate an energy beam, a gas flow system, or a guidance system configured to guide the energy beam to print the one or more three-dimensional objects in the enclosure.
  • a computer software product comprising a non-transitory computer-readable medium in which program instructions are stored, which instructions, when read by a computer, cause the computer to direct a mechanism used in the 3D printing process to implement (e.g., effectuate) any of the method disclosed herein, wherein the non- transitory computer-readable medium is operatively coupled to the mechanism.
  • Fig. 14 schematically illustrates a block diagram of various 3D printer components
  • Fig. 15 schematically illustrates various 3D printer components
  • Fig. 16 schematically illustrates an example simulation of gas flow trajectories within across the height and width of an enclosure as part of the 3D printer;
  • Fig. 23 schematically illustrates a side view of a 3D printer and its components
  • Fig. 24 schematically illustrates a side view of a component of a 3D printer
  • Figs. 27A-27F schematically illustrate side views of components of one or more 3D printers
  • Fig. 28 schematically illustrates a side view of 3D printer components
  • Figs. 30A-30D schematically illustrate various cross sections of one or more 3D printer components
  • Fig. 31 schematically illustrates a side view of a component of a 3D printer
  • FIG. 32A-32B schematically illustrate perspective views of components of one or more 3D printers
  • Figs. 33A-33E schematically illustrate perspective views of various components of 3D printers
  • Figs. 34A and 34B each schematically illustrate various views of components of a 3D printer
  • Fig. 35 schematically illustrates a top view of an enclosure of a 3D printer
  • FIG. 36A-36D schematically illustrate top views of enclosures of various 3D printers
  • Fig. 37 schematically illustrates a top view of an enclosure of a 3D printer
  • Figs. 38A and 38B each schematically illustrate side views of components of a 3D printer
  • Fig. 40A schematically illustrates a partial cross section side view of a window holder
  • Fig. 40B schematically illustrates a partial cross section perspective view of a window holder
  • Fig. 40C schematically illustrates a perspective view of a window holder
  • FIG. 41 A schematically illustrates a perspective view of a window holder
  • Fig. 41 B schematically illustrates a perspective view, with portions of an outer wall shown as transparent, of a window holder;
  • Fig. 41 C schematically illustrates a portion of a gas outlet material
  • Fig. 42A schematically illustrates a view of multiple window holders
  • Fig. 42B schematically illustrates a perspective view of a window holder
  • Fig. 43A schematically illustrates a view of multiple window holders and an integrated manifold
  • FIG. 45B schematically illustrates a flow of gas in a processing chamber
  • FIG. 46A schematically illustrates a flow of gas in a processing chamber
  • FIG. 46B schematically illustrates a flow of gas in a processing chamber
  • FIG. 47 schematically illustrates a flow of gas in a processing chamber
  • FIG. 48 schematically illustrates a perspective view of a processing chamber with manifolds, and a perspective view of manifolds;
  • FIG. 49 schematically illustrates views of portions of a manifold and baffles
  • Fig. 50 schematically illustrates portions of a nozzle
  • Fig. 51 schematically illustrates a nozzle portions thereof, and associated components
  • Fig. 52 schematically illustrates a nozzle portions thereof, and associated components
  • Fig. 53 schematically illustrates various views of a nozzle and a portion thereof;
  • Fig. 54 schematically illustrates portions of a nozzle and simulations of flow of gas in a manifold;
  • Fig. 56 shows a flow chart
  • Fig. 57 shows a flow chart
  • Fig. 58 shows a flow chart
  • FIG. 59 schematically illustrates various views of a processing chamber, and portions of a gas flow system
  • Fig. 60 schematically illustrates various views of portions of a gas flow system and associated components.
  • a single X for example, it is meant to include the following: (1 ) a single X, (2) a single Y, (3) a single Z, (4) a single X and a single Y, (5) a single X and a single Z, (6) a single Y and a single Z, (7) a plurality of X, (8) a plurality of Y, (9) a plurality of Z, (10) a plurality of X and a single Y, (11) a plurality of X and a single Z, (12) a plurality of Y and a single X, (13) a plurality of Y and a single Z, (14) a plurality of Z and a single X, (15) a plurality of Z and a single Y, (16) a plurality X and a plurality Y, (17) a plurality X and a plurality Z, (18) a plurality Y and a plurality Z.
  • operatively coupled or “operatively connected” refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and/or first mechanism, e.g., including a first mechanism that is in signal communication with a second mechanism.
  • operatively connected refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and/or first mechanism, e.g., including a first mechanism that is in signal communication with a second mechanism.
  • configured to refers to an object or apparatus that is (e.g., structurally) configured to bring about an intended result.
  • Transformed material is a material that underwent a physical change.
  • the physical change can comprise a phase change.
  • the physical change can comprise fusing (e.g., melting or sintering), connecting, or bonding (e.g., physical, or chemical bond).
  • the physical change can be a phase transformation such as from a solid to a partially liquid, or to a liquid, phase.
  • the 3D printing process may comprise printing one or more layers of hardened material in a building cycle.
  • a building cycle as understood herein, comprises printing all (e.g., hardened, or solid) material layers of a print job, which may comprise printing one or more 3D objects above a platform and/or a base (e.g., in a single material bed).
  • Pre-transformed material is a material before it has been transformed (e.g., once transformed) by an energy beam during an upcoming 3D printing process, e.g., it is a starting material for an upcoming 3D printing process.
  • the pretransformed material may be a material that was, or was not, transformed prior to its use in the upcoming 3D printing process.
  • the pre-transformed material may be a material that was partially transformed prior to its use in the upcoming 3D printing process.
  • the pretransformed material may be a starting material for the upcoming 3D printing process.
  • the pre-transformed material may be liquid, solid, or semi-solid (e.g., gel).
  • the pre-transformed material may be a particulate material.
  • the particulate material may be a powder material.
  • the powder material may comprise solid particles of material(s).
  • the particulate material may comprise vesicles (e.g., containing liquid or semi-solid material).
  • the particulate material may comprise solid or semi-solid material particles.
  • the pretransformed material may have been transformed by a 3D printer process prior to the upcoming 3D printing process. For example, in a first 3D printing process (having a first build cycle), powder material was used to form a 3D object. A remainder of the powder material of the first 3D printing process may become a pre-transformed material for an upcoming second 3D printing process (having a second build cycle). Thus, even though the remainder powder of the first 3D printing process may comprise transformed material (e.g., bits of sintered powder), it is still considered a pre-transformed material relative to the second 3D printing process. The remainder can be filtered and otherwise recycled for use as a pretransformed material in the second 3D printing process.
  • transformed material e.g., bits of sintered powder
  • FLS Fundamental length scale
  • a FLS of an object may comprise a length, a width, a height, a diameter, a spherical equivalent diameter, or a diameter of a bounding sphere.
  • a three-dimensional object as used herein may refer to “one or more three-dimensional objects,” as applicable.
  • Real time as understood herein may be during at least part of the printing of a 3D object. Real time may be during a print operation. Real time may be during a print cycle.
  • Real time may comprise: during formation of (i) a 3D object, (ii) a layer of hardened material as part of the 3D object, (iii) a hatch line, or (iv) a melt pool.
  • a target surface may refer to (1) a surface of a build plane (e.g., an exposed surface of a material bed), (2) an exposed surface of a platform, (3) an exposed surface of a 3D object (or a portion thereof), (4) any exposed surface adjacent to an exposed surface of the material bed, platform, or 3D object, and/or (5) any other targeted surface.
  • Targeted may be by at least one transforming agent, e.g., an energy beam, or by a light source.
  • the ranges are meant to be inclusive, unless otherwise specified. For example, a range between value 1 and value 2 is meant to be inclusive and include value 1 and value 2. The inclusive range will span any value from about value 1 to about value 2.
  • the term “adjacent” or “adjacent to,” as used herein, includes ‘next to’, ‘adjoining’, ‘in contact with’, and ‘in proximity to.’
  • one or more of the features shown in a figure comprising a 3D printer and/or components thereof can be combined with one or more of the various features of other 3D printers and/or components thereof described herein.
  • a figure shown herein may not show certain features of a 3D printer and/or components thereof described herein. It should be understood that any such features can be incorporated within the 3D printer as desired and where suitable.
  • a 3D object may be formed by sequential addition of material or joining of pre-transformed material to form a structure in a controlled manner (e.g., under manual or automated control).
  • Pre-transformed material is a material before it has been transformed during the 3D printing process. The transformation can be effectuated by utilizing an energy beam and/or flux.
  • the pre-transformed material may be a material that was, or was not, transformed prior to its use in a 3D printing process.
  • the pre-transformed material may be a starting material for the 3D printing process.
  • the deposited pre-transformed material may be fused
  • Fusing, binding or otherwise connecting the material is collectively referred to herein as “transforming” the material. Fusing the material may refer to melting, smelting, or sintering a pre-transformed material.
  • Melting may comprise liquefying the material (e.g., transforming to a liquefied state).
  • a liquefied state refers to a state in which at least a portion of a transformed material is in a liquid state.
  • Melting may comprise liquidizing the material (e.g., transforming to a liquidus state).
  • a liquidus state refers to a state in which an entire transformed material is in a liquid state.
  • the apparatuses, methods, software, and/or systems provided herein are not limited to the generation of a single 3D object, but are may be utilized to generate one or more 3D objects simultaneously (e.g., in parallel) or separately (e.g., sequentially).
  • the multiplicity of 3D object may be formed in one or more material beds (e.g., powder bed). In some embodiments, a plurality of 3D objects is formed in one material bed.
  • 3D printing methodologies comprise extrusion, wire, granular, laminated, light polymerization, or powder bed and inkjet head 3D printing.
  • Extrusion 3D printing can comprise robo-casting, fused deposition modeling (FDM) or fused filament fabrication (FFF).
  • Wire 3D printing can comprise electron beam freeform fabrication (EBF3).
  • Granular 3D printing can comprise direct metal laser sintering (DMLS), electron beam melting (EBM), selective laser melting (SLM), selective heat sintering (SHS), or selective laser sintering (SLS).
  • Powder bed and inkjet head 3D printing can comprise plaster-based 3D printing (PP).
  • Laminated 3D printing can comprise laminated object manufacturing (LOM).
  • Light polymerized 3D printing can comprise stereo-lithography (SLA), digital light processing (DLP), or laminated object manufacturing (LOM).
  • 3D printing methodologies can comprise Direct Material Deposition (DMD).
  • the Direct Material Deposition may comprise, Laser Metal Deposition (LMD, also known as, Laser deposition welding).
  • 3D printing methodologies can comprise powder feed, or wire deposition.
  • 3D printing methodologies differ from methods traditionally used in semiconductor device fabrication (e.g., vapor deposition, etching, annealing, masking, or molecular beam epitaxy).
  • 3D printing may further comprise one or more printing methodologies that are traditionally used in semiconductor device fabrication.
  • 3D printing methodologies can differ from vapor deposition methods such as chemical vapor deposition, physical vapor deposition, or electrochemical deposition.
  • 3D printing may further include vapor deposition methods.
  • the deposited pre-transformed material within the enclosure is a liquid material, semi-solid material (e.g., gel), or a solid material (e.g., powder).
  • the deposited pre-transformed material within the enclosure can be in the form of a powder, wires, sheets, or droplets.
  • the material e.g., pre-transformed, transformed, and/or hardened
  • the allotrope of elemental carbon may comprise amorphous carbon, graphite, graphene, diamond, or fullerene.
  • the fullerene may be selected from the group consisting of a spherical, elliptical, linear, and tubular fullerene.
  • the fullerene may comprise a buckyball, or a carbon nanotube.
  • the ceramic material may comprise cement.
  • the ceramic material may comprise alumina, zirconia, or carbide (e.g., silicon carbide, or tungsten carbide).
  • the ceramic material may include high performance material (HPM).
  • the ceramic material may include a nitride (e.g., boron nitride or aluminum nitride).
  • the material may comprise sand, glass, or stone.
  • the material may comprise an organic material, for example, a polymer or a resin (e.g., 114 W resin).
  • the organic material may comprise a hydrocarbon.
  • the polymer may comprise styrene or nylon (e.g., nylon 11).
  • the polymer may comprise a thermoplast.
  • the organic material may comprise carbon and hydrogen atoms.
  • the organic material may comprise carbon and oxygen atoms.
  • the organic material may comprise carbon and nitrogen atoms.
  • the organic material may comprise carbon and sulfur atoms.
  • the material may exclude an organic material.
  • the material may comprise a solid or a liquid.
  • the material may comprise a silicon- based material, for example, silicon based polymer or a resin.
  • the material may comprise an organosilicon-based material.
  • the material may comprise silicon and hydrogen atoms.
  • the material may comprise silicon and carbon atoms. In some embodiments, the material may exclude a silicon-based material.
  • the powder material may be coated by a coating (e.g., organic coating such as the organic material (e.g., plastic coating)).
  • the material may be devoid of organic material.
  • the liquid material may be compartmentalized into reactors, vesicles, or droplets. The compartmentalized material may be compartmentalized in one or more layers.
  • the material may be a composite material comprising a secondary material.
  • the secondary material can be a reinforcing material (e.g., a material that forms a fiber).
  • the reinforcing material may comprise a carbon fiber, Kevlar®, Twaron®, ultra-high-molecular- weight polyethylene, or glass fiber.
  • the material can comprise powder (e.g., granular material) and/or wires.
  • the bound material can comprise chemical bonding.
  • Transforming can comprise chemical bonding. Chemical bonding can comprise covalent bonding.
  • the pretransformed material may be pulverous.
  • the printed 3D object can be made of a single material (e.g., single material type) or multiple materials (e.g., multiple material types).
  • the material may be a single material type (e.g., a single alloy or a single elemental metal).
  • the material may comprise one or more material types.
  • the material may comprise two alloys, an alloy and an elemental metal, an alloy and a ceramic, or an alloy and an elemental carbon.
  • the material may comprise an alloy and alloying elements (e.g., for inoculation).
  • the material may comprise blends of material types.
  • the material may comprise blends with elemental metal or with metal alloy.
  • the material may comprise blends excluding (e.g., without) elemental metal or including (e.g., with) metal alloy.
  • the material may comprise a stainless steel.
  • the material may comprise a titanium alloy, aluminum alloy, and/or nickel alloy.
  • a layer within the 3D object comprises a single type of material.
  • a layer of the 3D object may comprise a single elemental metal type, or a single alloy type.
  • a layer within the 3D object may comprise several types of material (e.g., an elemental metal and an alloy, an alloy and a ceramic, an alloy and an elemental carbon). In certain embodiments, each type of material comprises only a single member of that type.
  • a single member of elemental metal e.g., iron
  • a single member of metal alloy e.g., stainless steel
  • a single member of ceramic material e.g., silicon carbide or tungsten carbide
  • a single member of elemental carbon e.g., graphite
  • a layer of the 3D object comprises more than one type of material. In some cases, a layer of the 3D object comprises more than member of a type of material.
  • the material bed, build platform (also referred to herein as platform), or both material bed and platform comprise a material type which constituents (e.g., atoms) readily lose their outer shell electrons, resulting in a free-flowing cloud of electrons within their otherwise solid arrangement.
  • the powder, the base, or both the powder and the base comprise a material characterized in having high electrical conductivity, low electrical resistivity, high thermal conductivity, or high density.
  • the high electrical conductivity can be at least about 1 * 10 5 Siemens per meter (S/m), 5 * 10 5 S/m,
  • the high electrical conductivity can be between any of the afore-mentioned electrical conductivity values (e.g., from about 1 * 10 5 S/m to about 1 * 10 s S/m).
  • the thermal conductivity, electrical resistivity, electrical conductivity, and/or density can be measured at ambient temperature (e.g., at R.T., or 20°C).
  • the low electrical resistivity may be at most about 1 * 10 s ohm times meter (D * m), 5 * 10 6 D * m, 1 * 10 6 D * m,
  • the low electrical resistivity can be between any of the afore-mentioned values (e.g., from about 1X10 5 D * m to about 1X10 8 D * m).
  • the high thermal conductivity may be at least about 10 Watts per meter times Kelvin (W/mK), 15 W/mK, 20 W/mK, 35 W/mK, 50 W/mK, 100 W/mK, 150 W/mK, 200 W/mK, 205 W/mK, 300 W/mK, 350 W/mK, 400 W/mK, 450 W/mK, 500 W/mK, 550 W/mK, 600 W/mK, 700 W/mK, 800 W/mK, 900 W/mK, or 1000 W/mK.
  • the high thermal conductivity can be between any of the afore-mentioned thermal conductivity values (e.g., from about 20 W/mK to about 1000 W/mK).
  • the high density may be at least about 1 .5 grams per cubic centimeter (g/cm 3 ), 1.7 g/cm 3 , 2 g/cm 3 , 2.5 g/cm 3 , 2.7 g/cm 3 , 3 g/cm 3 , 4 g/cm 3 , 5 g/cm 3 , 6 g/cm 3 , 7 g/cm 3 , 8 g/cm 3 , 9 g/cm 3 , 10 g/cm 3 , 11 g/cm 3 , 12 g/cm 3 , 13 g/cm 3 , 14 g/cm 3 , 15 g/cm 3 , 16 g/cm 3 , 17 g/cm 3 , 18 g/cm 3 , 19 g/cm 3 , 20 g/cm 3 , or 25 g/cm 3 .
  • the elemental metal is an alkali metal, an alkaline earth metal, a transition metal, a rare-earth element metal, or another metal.
  • the alkali metal can be Lithium, Sodium, Potassium, Rubidium, Cesium, or Francium.
  • the alkali earth metal can be Beryllium, Magnesium, Calcium, Strontium, Barium, or Radium.
  • the transition metal can be Scandium, Titanium, Vanadium, Chromium, Manganese, Iron, Cobalt, Nickel, Copper, Zinc, Yttrium, Zirconium, Platinum, Gold, Rutherfordium, Dubnium, Seaborgium, Bohrium, Hassium, Meitnerium, Ununbium, Niobium, Iridium, Molybdenum, Technetium, Ruthenium, Rhodium, Palladium, Silver, Cadmium, Hafnium, Tantalum, Tungsten, Rhenium or Osmium.
  • the transition metal can be mercury.
  • the rare-earth metal can be a lanthanide or an actinide.
  • the antinode metal can be Lanthanum, Cerium, Praseodymium, Neodymium, Promethium, Samarium, Europium, Gadolinium, Terbium, Dysprosium, Holmium, Erbium, Thulium, Ytterbium, or Lutetium.
  • the actinide metal can be Actinium, Thorium, Protactinium, Uranium, Neptunium, Plutonium, Americium, Curium, Berkelium, Californium, Einsteinium, Fermium, Mendelevium, Nobelium, or Lawrencium.
  • the other metal can be Aluminum, Gallium, Indium, Tin, Thallium, Lead, or Bismuth.
  • the material may comprise a precious metal.
  • the precious metal may comprise gold, silver, palladium, ruthenium, rhodium, osmium, iridium, or platinum.
  • the material may comprise at least about 40%, 50%, 60%, 70%, 80%, 90%, 95%, 97%, 98%, 99%, 99.5% or more precious metal.
  • the powder material may comprise at most about 40%, 50%, 60%, 70%, 80%, 90%, 95%, 97%, 98%, 99%,
  • the material may comprise precious metal with any value in between the afore-mentioned values.
  • the material may comprise at least a minimal percentage of precious metal according to the laws in the particular jurisdiction.
  • the metal alloy comprises iron based alloy, nickel based alloy, cobalt based alloy, chrome based alloy, cobalt chrome based alloy, titanium based alloy, magnesium based alloy, or copper based alloy.
  • the alloy may comprise an oxidation or corrosion resistant alloy.
  • the alloy may comprise a super alloy (e.g., Inconel).
  • the super alloy may comprise Inconel 600, 617, 625, 690, 718 or X-750.
  • the alloy may comprise an alloy used for aerospace applications, automotive application, surgical application, or implant applications.
  • the metal may include a metal used for aerospace applications, automotive application, surgical application, or implant applications.
  • the super alloy may comprise IN 738 LC, IN 939, Rene 80, IN 6203 (e.g., IN 6203 DS), PWA 1483 (e.g., PWA 1483 SX), or Alloy 247.
  • the metal alloys are Refractory Alloys.
  • the refractory metals and alloys may be used for heat coils, heat exchangers, furnace components, or welding electrodes.
  • the Refractory Alloys may comprise a high melting points, low coefficient of expansion, mechanically strong, low vapor pressure at elevated temperatures, high thermal conductivity, or high electrical conductivity.
  • the material e.g., alloy or elemental
  • the material comprises a material used for applications in industries comprising aerospace (e.g., aerospace super alloys), jet engine, missile, automotive, marine, locomotive, satellite, defense, oil & gas, energy generation, semiconductor, fashion, construction, agriculture, printing, or medical.
  • the material may comprise an alloy used for products comprising, devices, medical devices (human & veterinary), machinery, cell phones, semiconductor equipment, generators, engines, pistons, electronics (e.g., circuits), electronic equipment, agriculture equipment, motor, gear, transmission, communication equipment, computing equipment (e.g., laptop, cell phone, i-pad), air conditioning, generators, furniture, musical equipment, art, jewelry, cooking equipment, or sport gear.
  • the material may comprise an alloy used for products for human or veterinary applications comprising implants, or prosthetics.
  • the metal alloy may comprise an alloy used for applications in the fields comprising human or veterinary surgery, implants (e.g., dental), or prosthetics.
  • the alloy includes a high-performance alloy.
  • the alloy may include an alloy exhibiting at least one of excellent mechanical strength, resistance to thermal creep deformation, good surface stability, resistance to corrosion, and resistance to oxidation.
  • the alloy may include a face-centered cubic austenitic crystal structure.
  • the alloy may comprise Hastelloy, Inconel, Waspaloy, Rene alloy (e.g., Rene-80, Rene-77, Rene-220, or Rene-41), Scandium alloy, Haynes alloy, Incoloy, MP98T, TMS alloy, MTEK (e.g., MTEK grade MAR-M-247, MAR-M-509, MAR-M-R41 , or MAR-M-X-45), or CMSX (e.g., CMSX-3, or CMSX-4).
  • the alloy can be a single crystal alloy.
  • the iron-based alloy comprises Elinvar, Fernico, Ferroalloys, Invar, Iron hydride, Kovar, Spiegeleisen, Staballoy (stainless steel), or Steel.
  • the metal alloy is steel.
  • the Ferroalloy may comprise Ferroboron, Ferrocerium, Ferrochrome, Ferromagnesium, Ferromanganese, Ferromolybdenum, Ferronickel, Ferrophosphorus, Ferrosilicon, Ferrotitanium, Ferrouranium, or Ferrovanadium.
  • the iron- based alloy may include cast iron or pig iron.
  • the steel may include Bulat steel, Chromoly, Crucible steel, Damascus steel, Hadfield steel, High speed steel, HSLA steel, Maraging steel, Maraging Steel (M300), Reynolds 531 , Silicon steel, Spring steel, Stainless steel, Tool steel, Weathering steel, or Wootz steel.
  • the high-speed steel may include Mushet steel.
  • the stainless steel may include AL-6XN, Alloy 20, celestrium, marine grade stainless, Martensitic stainless steel, surgical stainless steel, or Zeron 100.
  • the tool steel may include Silver steel.
  • the steel may comprise stainless steel, Nickel steel, Nickel-chromium steel, Molybdenum steel, Chromium steel, Chromium-vanadium steel, Tungsten steel, Nickel-chromium- molybdenum steel or Silicon-manganese steel.
  • the steel may be comprised of any Society of Automotive Engineers (SAE) grade such as 440F, 410, 312, 430, 440A, 440B, 440C, 304, 305, 304L, 304L, 301 , 304LN, 301 LN, 2304, 316, 316LN, 316L, 317L, 2205, 409, 904L, 321 , 254SMO, 316Ti, 321 H, 17-4, 15-5, 420 or 304H.
  • SAE Society of Automotive Engineers
  • the steel may comprise stainless steel of at least one crystalline structure selected from the group consisting of austenitic, superaustenitic, ferritic, martensitic, duplex and precipitation-hardening martensitic.
  • Duplex stainless steel may be lean duplex, standard duplex, super duplex or hyper duplex.
  • the stainless steel may comprise surgical grade stainless steel (e.g., austenitic 316, martensitic 420 or martensitic 440).
  • the austenitic 316 stainless steel may include 316L or 316LVM.
  • the steel may include 17-4 Precipitation Hardening steel (also known as type 630 is a chromium-copper precipitation hardening stainless steel; 17-4PH steel).
  • the stainless steel may comprise 360L stainless steel.
  • the titanium-based alloys include alpha alloys, near alpha alloys, alpha and beta alloys, or beta alloys.
  • the titanium alloy may comprise grade 1 , 2, 2H,
  • the titanium base alloy includes T ⁇ AI 6 n or TiAI 6 Nb7.
  • the Nickel based alloy includes Alnico, Alumel, Chromel, Cupronickel, Ferronickel, German silver, Hastelloy, Inconel, Monel metal, Nichrome, Nickel- carbon, Nicrosil, Nisil, Nitinol, Hastelloy X, Cobalt-Chromium or Magnetically "soft” alloys.
  • the magnetically “soft” alloys may comprise Mu-metal, Permalloy, Supermalloy, or Brass.
  • the Brass may include nickel hydride, stainless or coin silver.
  • the cobalt alloy may include Megallium, Stellite (e. g. Talonite), Ultimet, or Vitallium.
  • the chromium alloy may include chromium hydroxide, or Nichrome.
  • the aluminum-based alloy includes AA-8000, Al-Li (aluminum- lithium), Alnico, Duralumin, Hiduminium, Kryron Magnalium, Nambe, Scandium- aluminum, or, Y alloy.
  • the magnesium alloy may be Elektron, Magnox or T-Mg-AI-Zn (Bergman phase) alloy. At times, the material excludes at least one aluminum-based alloy (e.g., AIShoMg).
  • the copper based alloy comprises Arsenical copper, Beryllium copper, Billon, Brass, Bronze, Constantan, Copper hydride, Copper-tungsten, Corinthian bronze, Cunife, Cupronickel, Cymbal alloys, Devarda's alloy, Electrum,
  • the Brass may include Calamine brass, Chinese silver, Dutch metal, Gilding metal, Muntz metal, Pinchbeck, Prince's metal, or Tombac.
  • the Bronze may include Aluminum bronze, Arsenical bronze, Bell metal, Florentine bronze, Guanin, Gunmetal, Glucydur, Phosphor bronze, Ormolu or Speculum metal.
  • the copper alloy may be a high- temperature copper alloy (e.g., GRCop-84).
  • the elemental carbon comprises graphite, Graphene, diamond, amorphous carbon, carbon fiber, carbon nanotube, or fullerene.
  • the material comprises powder material (also referred to herein as a “pulverous material”).
  • the powder material may comprise a solid comprising fine particles.
  • the powder may be a granular material.
  • the powder can be composed of individual particles. At least some of the particles can be spherical, oval, prismatic, cubic, or irregularly shaped. At least some of the particles can have a fundamental length scale (e.g., radius, diameter, spherical equivalent diameter, length, width, depth, or diameter of a bounding sphere, or radius of a bounding sphere).
  • the fundamental length scale (abbreviated herein as “FLS”) of at least some of the particles can be from about 1 nanometers (nm) to about 1000 micrometers (microns), 500 microns, 400 microns, 300 microns, 200 microns, 100 microns, 50 microns, 40 microns, 30 microns, 20 microns, 10 microns, 1 micron, 500 nm, 400 nm, 300 nm, 200 nm, 100 nm, 50 nm, 40 nm, 30 nm, 20 nm, 10 nm, or 5nm.
  • At least some of the particles can have a FLS of at least about 1000 micrometers (microns), 500 microns, 400 microns, 300 microns, 200 microns, 100 microns, 50 microns, 40 microns, 30 microns, 20 microns, 10 microns, 1 micron, 500 nm, 400 nm,
  • the particles can have a FLS of at most about 1000 micrometers (microns), 500 microns, 400 microns, 300 microns, 200 microns, 100 microns, 50 microns, 40 microns, 30 microns, 20 microns, 10 microns, 1 micron, 500 nm, 400 nm, 300 nm, 200 nm, 100 nm,
  • the powder particles may have a FLS in between any of the afore-mentioned FLSs.
  • the powder comprises a particle mixture, which particle comprises a shape.
  • the powder can be composed of a homogenously shaped particle mixture such that all of the particles have substantially the same shape and FLS magnitude within at most about 1%, 5%, 8%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 50%, 60%, 70%, or less distribution of FLS.
  • the powder can be a heterogeneous mixture such that the particles have variable shape and/or FLS magnitude.
  • at least about 30%, 40%, 50%, 60%, or 70% (by weight) of the particles within the powder material have a largest FLS that is smaller than the median largest FLS of the powder material.
  • at least about 30%, 40%, 50%, 60%, or 70% (by weight) of the particles within the powder material have a largest FLS that is smaller than the mean largest FLS of the powder material.
  • the size of the largest FLS of the transformed material is greater than the average largest FLS of the powder material by at least about 1.1 times, 1 .2 times, 1.4 times, 1.6 times, 1.8 times, 2 times, 4 times, 6 times, 8 times, or 10 times. In some examples, the size of the largest FLS of the transformed material is greater than the median largest FLS of the powder material by at most about 1.1 times, 1 .2 times,
  • the powder material can have a median largest FLS that is at least about 1 pm, 5 pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 100 pm, or 200 pm.
  • the powder material can have a median largest FLS that is at most about 1 pm, 5 pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 100 pm, or 200 pm.
  • the powder particles may have a FLS in between any of the FLS listed above (e.g., from about 1 pm to about 200 pm, from about 1 pm to about 50 pm, or from about 5 pm to about 40 pm).
  • a system for generating a 3D object comprising: an enclosure for accommodating at least one layer of pre-transformed material (e.g., powder); an energy (e.g., energy beam) capable of transforming the pre-transformed material to form a transformed material; and a controller that directs the energy to at least a portion of the layer of pre-transformed material according to a path (e.g., as described herein).
  • the transformed material may be capable of hardening to form at least a portion of a 3D object.
  • the system may comprise an energy source, an optical system (e.g., Fig.
  • the chamber may comprise a building platform.
  • the system for generating a 3D object and its components may be any 3D printing system such as, for example, the one described in Patent Application serial number PCT/US15/36802 filed on June 19, 2015, titled “APPARATUSES, SYSTEMS AND METHODS FOR THREE-DIMENSIONAL PRINTING” or in Provisional Patent Application serial number 62/317,070 filed April 1 , 2016, titled “APPARATUSES, SYSTEMS AND METHODS FOR EFFICIENT THREE-DIMENSIONAL PRINTING”, both of which are entirely incorporated herein by references.
  • the 3D printing system comprises a chamber (e.g., Fig. 1 , 116; Fig. 2, 216).
  • Components of Fig. 1 can be disposed relative to gravitational vector 199 pointing to gravitational center G.
  • Components of Fig. 2 can be disposed relative to gravitational vector 299 pointing to gravitational center G.
  • the chamber may be referred herein as the “processing chamber.”
  • the processing chamber may comprise an energy beam (e.g., Fig. 1 , 101 ; Fig. 2, 204).
  • the energy beam may be directed towards an exposed surface of a material bed (e.g., Fig. 1 , 119).
  • the 3D printing system may comprise one or more modules (e.g., Fig. 2, 201 , 202, and 203).
  • the one or more modules may be referred herein as the “build modules.”
  • at least one build module e.g., Fig. 1 , 123 may be situated in the enclosure comprising the processing chamber (e.g., Fig. 1 , 116).
  • at least one build module may engage with the processing chamber (e.g., Fig. 1).
  • at least one build module may not engage with the processing chamber (e.g., Fig. 2).
  • a plurality of build modules e.g., Fig.
  • the build module may reversibly engage with (e.g., couple to) the processing chamber.
  • the engagement of the build module with the processing chamber may be controlled (e.g., by a controller). The control may be automatic and/or manual.
  • the engagement of the build module with the processing chamber may be reversible. In some embodiments, the engagement of the build module with the processing chamber may be permanent.
  • the FLS (e.g., width, depth, and/or height) of the processing chamber and/or the build plate can be at least about 50 millimeters (mm), 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 250 mm, 280 mm, 320 mm, 400 mm, 450 mm, 500 mm, 800 mm, 900 mm, 1 meter (m), 2 m, or 5 m.
  • the FLS of the processing chamber and/or the build plate can be at most about 50 millimeters (mm), 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 250 mm, 400 mm, 500 mm, 800 mm, 900 mm, 1 meter (m), 2 m, or 5 m.
  • the FLS of the processing chamber and/or the build plate can be between any of the afore-mentioned values (e.g., 50 mm to about 5m, from about 250 mm to about 500 mm, or from about 500 mm to about 5m).
  • the build module is operatively coupled to at least one controller.
  • At least one of the build modules may have a controller.
  • the controller may be its own controller.
  • the controller may be different than the controller controlling the 3D printing process and/or the processing chamber.
  • the translation facilitator e.g., build module delivery system
  • the controller of the translation facilitator may be different than the controller controlling the 3D printing process and/or the processing chamber.
  • the controller of the translation facilitator may be different than the controller of the build module.
  • the build module controller and/or the translation facilitator controller may be a microcontroller. At times, the controller of the 3D printing process and/or the processing chamber may not interact with the controller of the build module and/or translation facilitator.
  • the controller of the build module and/or translation facilitator may not interact with the controller of the 3D printing process and/or the processing chamber.
  • the controller of the build module may not interact with the controller of the processing chamber.
  • the controller of the translation facilitator may not interact with the controller of the processing chamber.
  • the controller of the 3D printing process and/or the processing chamber may be able to interpret one or more signals emitted from (e.g., by) the build module and/or translation facilitator.
  • the controller of the build module and/or translation facilitator may be able to interpret one or more signals emitted from (e.g., by) the processing chamber.
  • the one or more signals may be electromagnetic, electronic, magnetic, pressure, or sound signals.
  • the electromagnetic signals may comprise visible light, infrared, ultraviolet, or radio frequency signals.
  • the electromagnetic signals may comprise a radio frequency identification signal (RFID).
  • RFID radio frequency identification signal
  • the RFID may be specific for a build module, user, entity, 3D object model, processor, material type, printing instruction, 3D print job, or any combination thereof.
  • the build module controller controls the translation of the build module, sealing status of the build module, atmosphere of the build module, engagement of the build module with the processing chamber, exit of the build module from the enclosure, entry of the build module into the enclosure, or any combination thereof.
  • Controlling the sealing status of the build module may comprise opening or closing of the build module shutter.
  • the build chamber controller may be able to interpret signals from the 3D printing controller and/or processing chamber controller.
  • the processing chamber controller may be the 3D printing controller.
  • the build module controller may be able to interpret and/or respond to a signal regarding the atmospheric conditions in the load lock.
  • the build module controller may be able to interpret and/or respond to a signal regarding the completion of a 3D printing process (e.g., when the printing of a 3D object is complete).
  • the build module may be connected to an actuator.
  • the actuator may be translating or stationary.
  • the controller of the build module may direct the translation facilitator (e.g., actuator) to translate the build module from one position to another (e.g., arrows 221-224 in Fig. 2), when translation is possible.
  • the translation facilitator may be a build module delivery system.
  • the translation facilitator may be autonomous.
  • the translation facilitator may operate independently of the 3D printer (e.g., mechanisms directed by the 3D printing controller).
  • the translation facilitator (e.g., build module delivery system) may comprise a controller and/or a motor.
  • the translation facilitator may comprise a machine or a human.
  • the translation is possible, for example, when the destination position of the build module is empty.
  • the controller of the 3D printing and/or the processing chamber may be able to sense signals emitted from the controller of the build module.
  • the controller of the 3D printing and/or the processing chamber may be able to sense a signal from the build module that is emitted when the build module is docked into engagement position with the processing chamber.
  • the signal from the build module may comprise reaching a certain position in space, reaching a certain atmospheric characteristic threshold, opening or shutting the build platform closing, or engaging or disengaging (e.g., docking or undocking) from the processing chamber.
  • the build module may comprise one or more sensors.
  • the build module may comprise a proximity, movement, light, sounds, or touch sensor.
  • the build module is included as part of the 3D printing system. In some embodiments, the build module is separate from the 3D printing system.
  • the build module may be independent (e.g., operate independently) from the 3D printing system.
  • build module may comprise its own controller, motor, elevator, build platform, valve, channel, and/or shutter. In some embodiments, one or more conditions differ between the build module and the processing chamber, and/or among the different build modules.
  • the difference may comprise different pre-transformed materials, atmospheres, platforms, temperatures, pressures, humidity levels, an oxidizing gas (e.g., oxygen) level, gas type (e.g., inert), traveling speed (e.g., of the build modules), traveling method (e.g., of the build modules), acceleration speed (e.g., of the build modules), or post processing treatment (e.g., within the processing chamber and/or build module(s)).
  • the difference may comprise different reactive agent levels.
  • gas may comprise one or more gasses.
  • the relative velocity of the various build modules with respect to the processing chamber may be different, similar, or substantially similar.
  • the build platform may undergo different, similar, or substantially similar post processing treatment (e.g., further processing of the 3D object and/or material bed after the generation of the 3D object in the material bed is complete).
  • At least one build module translates relative to the processing chamber.
  • the translation may be parallel or substantially parallel to the bottom surface of the build chamber.
  • the bottom surface of the build chamber is the one closest to the gravitational center.
  • the translation may be at an angle (e.g., planar or compound) relative to the bottom surface of the build chamber.
  • the translation may use any device that facilitates translation (e.g., an actuator).
  • the translation facilitator may comprise a robotic arm, conveyor (e.g., conveyor belt), rotating screw, or a moving surface (e.g., platform).
  • the translation facilitator may comprise a chain, rail, motor, or an actuator.
  • the translation facilitator may comprise a component that can move another.
  • the movement may be controlled (e.g., using a controller).
  • the movement may comprise using a control signal and source of energy (e.g., electricity).
  • the translation facilitator may use electricity, pneumatic pressure, hydraulic pressure, or human power.
  • the 3D printing system comprises a plurality of build modules.
  • the 3D printing system may comprise at least 1 , 2, 3, 4, 5, 6, 7, 8, 9, or 10 build modules.
  • Fig. 2 shows an example of three build modules (e.g., 201 , 202, and 203) and one processing chamber 210. Examples of enclosures, build modules, unpacking stations, processing chambers and their components can be found in PCT patent application serial number PCT/US17/39422, which is incorporated herein by reference in its entirety.
  • At least one build module engages with the processing chamber to expand the interior volume of the processing chamber (e.g., into the volume of the engaged build module).
  • the atmospheres of the chamber and enclosure may merge.
  • the atmospheres of the chamber and enclosure may remain separate.
  • the atmospheres of the build module and processing chamber may be separate.
  • the build module may be mobile or stationary.
  • the build module may comprise an elevator.
  • the elevator may be connected to a platform (e.g., building platform).
  • the elevator may be reversibly connected to at least a portion of the platform (e.g., to the base).
  • the elevator may be irreversibly connected to at least a portion of the platform (e.g., to the substrate).
  • the platform may be separated from one or more walls (e.g., side walls) of the build module by a seal (e.g., Fig. 2, 211 ; Fig. 1 , 103).
  • the seal may be impermeable or substantially impermeable to gas.
  • the seal may be permeable to gas.
  • the seal may be flexible.
  • the seal may be elastic.
  • the seal may be bendable.
  • the seal may be compressible.
  • the seal may comprise rubber (e.g., latex), Teflon, plastic, or silicon.
  • the seal may comprise a mesh, membrane, sieve, paper (e.g., filter paper), cloth (e.g., felt), or brush.
  • the mesh, membrane, paper and/or cloth may comprise randomly and/or non- randomly arranged fibers.
  • the paper may comprise a High-efficiency particulate arrestance filter (HEPA) filter.
  • HEPA High-efficiency particulate arrestance filter
  • the seal may be permeable to at least one gas, and impermeable to the pre-transformed (e.g., and to the transformed) material. The seal may not allow a pretransformed (e.g., and to the transformed) material to pass through.
  • the build module and/or processing chamber comprises an openable shutter.
  • the build module and processing chamber may each comprise a separate openable shutter.
  • the shutter may be a seal, door, blockade, stopple, stopper, plug, piston, cover, roof, hood, block, stopple, obstruction, lid, closure, or a cap.
  • the shutter may be opened upon engagement of the build module with the processing chamber.
  • Fig. 1 shows an example of a processing chamber (e.g., Fig. 1 , 126) and a build module (e.g., Fig. 1 , 123).
  • the processing chamber comprises the energy beam (e.g., Fig. 1 , 101).
  • the build module comprises a build platform comprising a substrate (e.g., Fig. 1 , 109), a base (e.g., Fig. 1 , 102), and an elevator shaft (e.g., Fig. 1 , 105) that allows the platform to move vertically up and down.
  • the build module (e.g., Fig. 1 , 123) may comprise a shutter.
  • the processing chamber may comprise a shutter.
  • the shutter may be openable.
  • the shutter may be removable. The removal of the shutter may comprise manual or automatic removal.
  • the build module shutter may be opened while being connected to the build module.
  • the processing chamber shutter may be opened while being connected to the processing chamber (e.g., through connector).
  • the shutter connector may comprise a hinge, chain, or a rail.
  • the shutter may be opened in a manner similar to opening a door or a window.
  • the shutter may be opened by swiveling (e.g., similar to opening a door or a window held on a hinge).
  • the shutter may be opened by its removal from the opening which it blocks.
  • the removal may be guided (e.g., by a rail, arm, pulley, crane, or conveyor).
  • the guiding may be using a robot.
  • the guiding may be using at least one motor and/or gear.
  • the shutter may be opened while being disconnected from the build module.
  • the shutter may be opened similar to opening a lid.
  • the shutter may be opened by shifting or sliding (e.g., to a side).
  • the build module, processing chamber, and/or enclosure comprises one or more seals.
  • the seal may be a sliding seal or a top seal.
  • the build module and/or processing chamber may comprise a sliding seal that meets with the exterior of the build module upon engagement of the build module with the processing chamber.
  • the processing chamber may comprise a top seal that faces the build module and is pushed upon engagement of the processing chamber with the build module.
  • the build module may comprise a top seal that faces the processing chamber and is pushed upon engagement of the processing chamber with the build module.
  • the seal may be a face seal, or compression seal.
  • the seal may comprise an O-ring.
  • the build module, processing chamber, and/or enclosure is sealed, sealable, or open.
  • the atmosphere of the build module, processing chamber, and/or enclosure may be regulated.
  • the build module may be sealed, sealable, or open.
  • the processing chamber may be sealed, sealable, or open.
  • the enclosure may be sealed, sealable, or open.
  • the build module, processing chamber, and/or enclosure may comprise a valve and/or a gas opening-port.
  • the valve and/or a gas opening-port may be below, or above the building platform.
  • the valve and/or a gas opening-port may be disposed at the horizontal plane of the build platform.
  • the valve and/or a gas opening-port may be disposed at the adjacent to the build platform.
  • the valve may allow at least one gas to travel through.
  • the gas may enter or exit through the valve.
  • the gas may enter or exit the build module, processing chamber, and/or enclosure through the valve.
  • the atmosphere of the build module, processing chamber, and/or enclosure may be individually controlled.
  • the atmosphere of at least two of the build module, processing chamber, and enclosure may be separately controlled.
  • the atmosphere of at least two of the build module, processing chamber, and enclosure may be controlled in concert (e.g., simultaneously).
  • the atmosphere of at least one of the build module, processing chamber, or enclosure may be controlled by controlling the atmosphere of at least one of the build module, processing chamber, or enclosure in any combination or permutation.
  • the atmosphere in the build module is not controllable by controlling the atmosphere in the processing chamber.
  • the 3D printing system comprises a load lock.
  • the load lock may be disposed between the processing chamber and the build module.
  • the load lock may be formed by engaging the build module with the processing chamber.
  • the load lock may be sealable.
  • the load lock may be sealed by engaging the build module with the processing chamber (e.g., directly or indirectly).
  • the load lock may comprise one or more gas opening-ports.
  • the load lock may comprise one or more gas transport channels.
  • the load lock may comprise one or more valves.
  • a gas transport channel may comprise a valve. The opening and/or closing of a first valve of the 3D printing system may or may not be coordinated with the opening and/or closing of a second valve of the 3D printing system.
  • the valve may be controlled automatically (e.g., by a controller) and/or manually.
  • the load lock may comprise a gas entry opening-port and a gas exit opening-port.
  • a pressure below ambient pressure e.g., of 1 atmosphere
  • a pressure exceeding ambient pressure e.g., of 1 atmosphere
  • a pressure below and/or above ambient pressure if formed in the load lock.
  • a pressure equal or substantially equal to ambient pressure is maintained (e.g., automatically and/or manually) in the load lock.
  • the load lock, building module, processing chamber, and/or enclosure may comprise a valve.
  • the valve may comprise a pressure relief, pressure release, pressure safety, safety relief, pilot-operated relief, low pressure safety, vacuum pressure safety, low and vacuum pressure safety, pressure vacuum release, snap acting, or modulating valve.
  • the valve may comply with the legal industry standards presiding the jurisdiction.
  • the volume of the load lock may be smaller than the volume within the build module and/or processing chamber.
  • the total volume within the load lock may be at most about 0.1%, 0.5%, 1%, 5%, 10%, 20%, 50%, or 80% of the total volume encompassed by the build module and/or processing chamber.
  • the total volume within the load lock may be between any of the afore-mentioned percentage values (e.g., from about 0.1% to about 80%, from about 0.1% to about 5%, from about 5% to about 20%, from about 20% to about 50%, or from about 50% to about 80%).
  • the percentage may be volume per volume percentage.
  • the atmosphere of the build module and/or the processing chamber is fluidly connected to the atmosphere of the load lock. At times, conditioning the atmosphere of the load lock will condition the atmosphere of the build module and/or the processing chamber that is fluidly connected to the load lock.
  • the fluid connection may comprise gas flow.
  • the fluid connection may be through a gas permeable seal and/or through a channel (e.g., a pipe).
  • the channel may be a sealable channel (e.g., using a valve).
  • the shutter of the build module engages with the shutter of the processing chamber.
  • the engagement may be spatially controlled. For example, when the shutter of the build module is within a certain gap distance from the processing chamber shutter, the build module shutter engages with the processing chamber shutter.
  • the gap distance may trigger an engagement mechanism.
  • the gap trigger may be sufficient to allow sensing of at least one of the shutters.
  • the engagement mechanism may comprise magnetic, electrostatic, electric, hydraulic, pneumatic, or physical force.
  • the physical force may comprise manual force.
  • the single unit may transfer (e.g., relocate, or move) away from the energy beam.
  • the engagement may trigger the transferring (e.g., relocating) of the build module shutter and the processing chamber shutter as a single unit.
  • removal of the shutter depends on reaching a certain (e.g., predetermined) level of at atmospheric characteristics comprising a gas content (e.g., relative gas content), gas pressure, oxidizing gas level, humidity, argon level, or nitrogen level.
  • the atmospheric characteristics may comprise a reactive agent level.
  • the oxidizing gas may comprise oxygen.
  • the oxidizing agent may comprise the oxidizing gas.
  • the certain level may be an equilibrium between an atmospheric characteristic in the build chamber and that atmospheric characteristics in the processing chamber.
  • the 3D printing process initiates after merging of the build module with the processing chamber.
  • the build platform may be at an elevated position (e.g., Fig. 2, 212).
  • the build platform may be a vertically reduced position (e.g., Fig. 2, 213).
  • the building module may translate between three positions during a 3D printing run.
  • the build module may enter to the enclosure from a position away from the engagement position with the processing chamber (e.g., Fig. 2, 201).
  • the build module may then advance toward the processing chamber (e.g., Fig. 2, 202), and engage with the processing chamber (e.g., as described herein).
  • the layer dispensing mechanism and energy beam will translate and form the 3D object within the material bed (e.g., as described herein), while the platform gradually lowers its vertical position.
  • the build module may disengage from the processing chamber and translate away from the processing chamber engagement position (e.g., Fig. 2, 203).
  • Disengagement of the build module from the processing chamber may include closing the processing chamber with its shutter, closing the build module with its shutter, or both closing the processing chamber shutter and closing the build module shutter.
  • Disengagement of the build module from the processing chamber may include maintaining the processing chamber atmosphere to be separate from the enclosure atmosphere, maintaining the build module atmosphere to be separate from the enclosure atmosphere, or maintaining both the processing chamber atmosphere and the build atmosphere separate from the enclosure atmosphere.
  • Disengagement of the build module from the processing chamber may include maintaining the processing chamber atmosphere to be separate from the ambient atmosphere, maintaining the build module atmosphere to be separate from the ambient atmosphere, or maintaining both the processing chamber atmosphere and the build atmosphere separate from the ambient atmosphere.
  • the building platform that is disposed within the build module before engagement with the processing chamber may be at its top most position, bottom most position, or anywhere between its top most position and bottom most position within the build module.
  • the usage of sealable build modules, processing chamber, and/or unpacking chamber allows a small degree of operator intervention, low degree of operator exposure to the pre-transformed material, and/or low down time of the 3D printer.
  • the 3D printing system may operate most of the time without an intermission.
  • the 3D printing system may be utilized for 3D printing most of the time. Most of the time may be at least about 50%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, or 99% of the time.
  • Most of the time may be between any of the afore-mentioned values (e.g., from about 50% to about 99%, from about 80% to about 99%, from about 90% to about 99%, or from about 95% to about 99% of the time.
  • the entire time includes the time during which the 3D printing system prints a 3D object, and time during which it does not print a 3D object. Most of the time may include operation during seven days a week and/or 24 hours during a day.
  • the processing chamber (e.g., Fig. 8, 826) comprises one or more side walls (e.g., 873).
  • the processing chamber may comprise at least one inlet (e.g., Fig. 8, 844, 846) coupled to a first of the processing chamber side walls.
  • the processing chamber may comprise at least one outlet (e.g., Fig. 8, 872) coupled to a side wall of the chamber.
  • the side wall that is connected to the inlet may not be connected to the outlet.
  • the side wall connected to the inlet may be different from the side wall connected to the outlet.
  • the inlet may be coupled to the first of the processing chamber side walls, and the outlet may be coupled to the second of the processing chamber side walls.
  • the first side wall may be different from the second side wall.
  • the outlet opening may be (e.g., fluidly) connected to a gas recycling system.
  • the outlet opening (or a supplemental outlet opening) may be adjacent to an optical window.
  • the outlet opening may be (e.g., fluidly) connected to a pump. Fluid connection may allow a gas to flow through.
  • the gas may flow through the opening due to a pressure difference between the two sides of the outlet opening.
  • the gas may be sucked through the outlet opening.
  • the gas may be pressurized through the outlet opening.
  • the pressure at the side of the opening away from the processing pressure may be lower than the pressure at the side of the outlet opening closer to the processing chamber.
  • the pressure at the two sides of the outlet opening may be (e.g., substantially) equal.
  • the temperature of the gas that flows to the processing chamber and/or processing cone may be temperature controlled.
  • the gas may be heated and/or cooled before, or during the time it flows into the processing chamber and/or cone.
  • the gas may flow through a heat exchanger and/or heat sink.
  • the gas may be temperature controlled outside and/or inside the processing chamber.
  • the gas may be temperature controlled at least one inlet to the processing chamber.
  • the temperature of the atmosphere in the processing chamber and/or cone may be kept (e.g., substantially) constant.
  • Substantially constant temperature may allow for a temperature fluctuation (e.g., error delta) of at most about 15°C, 12°C, 10°C, 5°C, 4°C, 3°C, 2°C, 1°C, or 0.5°C.
  • error delta e.g., error delta
  • the 3D printing system requires operation of maximum a single standard daily work shift.
  • the 3D printing system may require operation by a human operator working at most of about 8 hours (h), 7h, 6h, 5h, 4h, 3h, 2h, 1 h, or 0.5h a day.
  • the 3D printing system may require operation by a human operator working between any of the afore-mentioned time frames (e.g., from about 8h to about 0.5h, from about 8h to about 4h, from about 6h to about 3h, from about 3h to about 0.5h, or from about 2h to about 0.5h a day).
  • the 3D printing system requires operation of maximum a single standard work week shift.
  • the 3D printing system may require operation by a human operator working at most of about 50h, 40 h, 30h, 20h, 10h, 5h, or 1 h a week.
  • the 3D printing system may require operation by a human operator working between any of the afore-mentioned time frames (e.g., from about 40h to about 1 h, from about 40h to about 20h, from about 30h to about 10h, from about 20h to about 1 h, or from about 10h to about 1 h a week).
  • a single operator may support during his daily and/or weekly shift at least 1 , 2, 3, 4,
  • the enclosure and/or processing chamber of the 3D printing system may be opened to the ambient environment sparingly. In some embodiments, the enclosure and/or processing chamber of the 3D printing system may be opened by an operator (e.g., human) sparingly. Sparing opening may be at most once in at most every 1 ,
  • the 3D printer has a capacity of 1 , 2, 3, 4, or 5 full prints in terms of pre-transformed material (e.g., powder) reservoir capacity.
  • the 3D printer may have the capacity to print a plurality of 3D objects in parallel.
  • the 3D printer may be able to print at least 2, 3, 4, 5, 6, 7, 8, 9, or 103D objects in parallel.
  • the printed 3D object is retrieved soon after terminating the last transformation operation of at least a portion of the material bed. Soon after terminating may be at most about 1 day, 12 hours, 6 hours, 3 hours, 2 hours, 1 hour, 30 minutes, 15 minutes, 5 minutes, 240 seconds (sec), 220 sec, 200 sec, 180 sec, 160 sec, 140 sec, 120 sec, 100 sec, 80 sec, 60 sec, 40 sec, 20 sec, 10 sec, 9 sec, 8 sec, 7 sec, 6 sec, 5 sec, 4 sec, 3 sec, 2 sec, or 1 sec. Soon after terminating may be between any of the aforementioned time values (e.g., from about 1s to about 1day, from about 1s to about 1 hour, from about 30 minutes to about 1day, or from about 20s to about 240s).
  • time values e.g., from about 1s to about 1day, from about 1s to about 1 hour, from about 30 minutes to about 1day, or from about 20s to about 240s.
  • the 3D printer has a capacity of 1 , 2, 3, 4, or 5 full prints before requiring human intervention. Human intervention may be required for refilling the pre-transformed (e.g., powder) material, unloading the build modules, unpacking the 3D object, or any combination thereof.
  • the 3D printer operator may condition the 3D printer at any time during operation of the 3D printing system (e.g., during the 3D printing process). Conditioning of the 3D printer may comprise refilling the pre-transformed material that is used by the 3D printer, replacing gas source, or replacing filters. The conditioning may be with or without interrupting the 3D printing system. For example, refilling and unloading from the 3D printer can be done at any time during the 3D printing process without interrupting the 3D printing process. Conditioning may comprise refreshing the 3D printer.
  • the 3D printer comprises a filter.
  • the 3D printer may comprise at least one filter.
  • the filter may be a ventilation filter.
  • the ventilation filter may capture fine powder from the 3D printing system.
  • the filter may comprise a paper filter such as a high-efficiency particulate arrestance (HEPA) filter (a.k.a., high-efficiency particulate arresting or high-efficiency particulate air filter).
  • HEPA high-efficiency particulate arrestance
  • the ventilation filter may capture spatter.
  • the spatter may result from the 3D printing process.
  • the ventilator may direct the spatter in a desired direction (e.g., by using positive or negative gas pressure).
  • the ventilator may use vacuum.
  • the ventilator may use gas blow.
  • time lapse between the end of a first 3D printing cycle in a first material bed and the beginning of a second 3D printing cycle in a second material bed there is a time lapse between the end of a first 3D printing cycle in a first material bed and the beginning of a second 3D printing cycle in a second material bed.
  • the time lapse between the end of the first 3D printing cycle in a first material bed, and the beginning of the second 3D printing cycle in a second material bed may be at most about 60 minutes (min), 40 min, 30 min, 20 min, 15 min, 10 min, or 5 min.
  • the time lapse between the end of printing in a first material bed, and the beginning of printing in a second material bed may be between any of the afore-mentioned times (e.g., from about 60 min to about 5 min, from about 60 min to about 30 min, from about 30 min to about 5 min, from about 20 min to about 5 min, from about 20 min to about 10 min, or from about 15 min to about 5min).
  • the speed during which the 3D printing process proceeds is disclosed in Patent Application serial number PCT/US15/36802 that is incorporated herein in its entirety.
  • the generated 3D object requires very little or no further processing after its retrieval. Further processing may be post printing processing. Further processing may comprise trimming, as disclosed herein. Further processing may comprise polishing (e.g., sanding). In some cases, the generated 3D object can be retrieved and finalized without removal of transformed material and/or auxiliary support features.
  • the 3D object (e.g., solidified material) that is generated has an average deviation value from the intended dimensions (e.g., of a desired 3D object) of at most about 0.5 microns (pm), 1 pm, 3 pm, 10 pm, 30 pm, 100 pm, 300 pm or less.
  • the deviation can be any value between the afore-mentioned values.
  • the average deviation can be from about 0.5 pm to about 300 pm, from about 10 pm to about 50 pm, from about 15 pm to about 85 pm, from about 5 pm to about 45 pm, or from about 15 pm to about 35 pm.
  • the 3D object can have a deviation from the intended dimensions in a specific direction, according to the formula Dv +I_/K*, wherein Dv is a deviation value, L is the length of the 3D object in a specific direction, and K* is a constant.
  • Dv can have a value of at most about 300 pm, 200 pm, 100 pm, 50 pm, 40 pm, 30 pm, 20 pm, 10 pm, 5 pm, 1 pm, or 0.5 pm.
  • Dv can have a value of at least about 0.5 pm, 1 pm, 3 pm, 5 pm, 10 pm, 20pm, 30 pm, 50 pm,
  • Dv can have any value between the afore-mentioned values.
  • Dv can have a value that is from about 0.5 pm to about 300 pm, from about 10 pm to about 50 pm, from about 15 pm to about 85 pm, from about 5 pm to about 45 pm, or from about 15 pm to about 35 pm.
  • K* can have a value of at most about 3000, 2500, 2000, 1500, 1000, or 500.
  • K dv can have a value of at least about 500, 1000, 1500, 2000, 2500, or 3000.
  • K dv can have any value between the afore-mentioned values.
  • K dv can have a value that is from about 3000 to about 500, from about 1000 to about 2500, from about 500 to about 2000, from about 1000 to about 3000, or from about 1000 to about 2500.
  • the generated 3D object requires a diminished amount of further processing.
  • the generated 3D object e.g., the printed 3D object
  • the printed 3D object may require further processing following its generation by a method described herein.
  • the printed 3D object may require reduced amount of processing after its generation by a method described herein.
  • the printed 3D object may not require removal of auxiliary support (e.g., since the printed 3D object was generated as a 3D object devoid of auxiliary support).
  • the printed 3D object may not require smoothing, flattening, polishing, or leveling.
  • the printed 3D object may not require further machining.
  • the printed 3D object may require one or more treatment operations following its generation (e.g., post generation treatment, or post printing treatment).
  • the further treatment step(s) may comprise surface scraping, machining, polishing, grinding, blasting (e.g., sand blasting, bead blasting, shot blasting, or dry ice blasting), annealing, or chemical treatment.
  • the further treatment may comprise physical or chemical treatment.
  • the further treatment step(s) may comprise electrochemical treatment, ablating, polishing (e.g., electro polishing), pickling, grinding, honing, or lapping.
  • the printed 3D object may require a single operation (e.g., of sand blasting) following its formation.
  • the printed 3D object may require an operation of sand blasting following its formation.
  • Polishing may comprise electro polishing (e.g., electrochemical polishing or electrolytic polishing).
  • the further treatment may comprise the use of abrasive(s).
  • the blasting may comprise sand blasting or soda blasting.
  • the chemical treatment may comprise use or an agent.
  • the agent may comprise an acid, a base, or an organic compound.
  • the further treatment step(s) may comprise adding at least one added layer (e.g., cover layer).
  • the added layer may comprise lamination.
  • the added layer may be of an organic or inorganic material.
  • the added layer may comprise elemental metal, metal alloy, ceramic, or elemental carbon.
  • the added layer may comprise at least one material that composes the printed 3D object.
  • the bottom most surface layer of the treated object may be different than the original bottom most surface layer that was formed by the 3D printing (e.g., the bottom skin layer).
  • the methods described herein can be performed in the enclosure (e.g., container, processing chamber, and/or build module).
  • One or more 3D objects can be formed in the enclosure (e.g., simultaneously and/or sequentially).
  • the enclosure may have a predetermined and/or controlled pressure.
  • the enclosure may have a predetermined and/or controlled atmosphere.
  • the control may be manual or via a control system.
  • the atmosphere may comprise at least one gas.
  • the enclosure comprises a gas pressure.
  • the enclosure may comprise ambient pressure (e.g., 1 atmosphere), negative pressure (e.g., vacuum) or positive pressure.
  • Different portions of the enclosure may have different atmospheres.
  • the different atmospheres may comprise different gas compositions.
  • the different atmospheres may comprise different atmosphere temperatures.
  • the different atmospheres may comprise ambient pressure (e.g., 1 atmosphere), negative pressure (e.g., vacuum) or positive pressure.
  • the different portions of the enclosure may comprise the processing chamber, build module, or enclosure volume excluding the processing chamber and/or build module.
  • the vacuum may comprise pressure below 1 bar, or below 1 atmosphere.
  • the positively pressurized environment may comprise pressure above 1 bar or above 1 atmosphere.
  • the pressure in the enclosure can be at least about 10 7 Torr, 10 6 Torr, 10 5 Torr, 10 4 Torr, 10 3 T orr, 10 2 Torr, 10 -1 Torr, 1 Torr, 10 T orr, 100 Torr, 1 bar, 2 bar, 3 bar, 4 bar, 5 bar, 10 bar,
  • the pressure in the enclosure can be at least about 100 Torr, 200 Torr, 300 Torr, 400 Torr, 500 Torr, 600 Torr, 700 Torr, 720 Torr, 740 Torr, 750 Torr, 760 Torr, 900 Torr,
  • the pressure in the enclosure can be between any of the afore-mentioned enclosure pressure values (e.g., from about 1 O 7 Torr to about 1200 Torr, from about 10 7 Torr to about 1 Torr, from about 1 Torr to about 1200 Torr, or from about 10 2 Torr to about 10 Torr).
  • the chamber can be pressurized to a pressure of at least 1 O 7 Torr, 1 O 6 Torr, 1 O 5 Torr, 1 O 4 Torr, 1 O 3 Torr, 1 O 2 Torr, 10 1 Torr, 1 Torr, 10 Torr, 100 Torr, 1 bar, 2 bar, 3 bar, 4 bar, 5 bar, 10 bar, 20 bar, 30 bar, 40 bar, 50 bar, 100 bar, 200 bar, 300 bar, 400 bar, 500 bar, or 1000 bar.
  • the chamber can be pressurized to a pressure of at most 10 7 Torr, 10 6 Torr, 10 5 Torr, 10 4 Torr, 10 3 Torr, 10 2 Torr, 10 1 Torr, 1 Torr, 10 Torr, 100 Torr, 1 bar, 2 bar, 3 bar, 4 bar, 5 bar, 10 bar, 20 bar, 30 bar, 40 bar, 50 bar, 100 bar, 200 bar, 300 bar, 400 bar, 500 bar, or 1000 bar.
  • the pressure in the chamber can be at a range between any of the afore-mentioned pressure values (e.g., from about 10 7 Torr to about 1000 bar, from about 1 O 7 Torr to about 1 Torr, from about 1 Torr to about 100 Barr, from about 1 bar to about 10 bar, from about 1 bar to about 100 bar, or from about 100 bar to about 1000 bar).
  • the chamber pressure can be standard atmospheric pressure.
  • the pressure may be measured at an ambient temperature (e.g., room temperature, 20°C, or 25°C).
  • the enclosure includes an atmosphere comprising at least one gas.
  • the enclosure may comprise a (e.g., substantially) inert atmosphere.
  • the atmosphere in the enclosure may be (e.g., substantially) depleted by one or more gases present in the ambient atmosphere.
  • the atmosphere in the enclosure may include a reduced level of one or more gases relative to the ambient atmosphere.
  • the atmosphere may be substantially depleted, or have reduced levels of water (e.g., humidity), oxidizing gas (e.g., oxygen), nitrogen, carbon dioxide, hydrogen sulfide, or any combination thereof.
  • the atmosphere may be substantially depleted, or have reduced levels of a reactive agent.
  • the level of the depleted or reduced level may be at most about 1 ppm, 10 ppm, 50 ppm, 100 ppm, 500 ppm, 1000 ppm, 5000 ppm, 10000 ppm, 25000 ppm, 50000 ppm, or 70000 ppm volume by volume (v/v).
  • the level of the depleted or reduced level may be at least about 1 ppm, 10 ppm, 50 ppm, 100 ppm, 500 ppm, 1000 ppm, 5000 ppm, 10000 ppm, 25000 ppm, 50000 ppm, or 70000 ppm (v/v).
  • the level (e.g., depleted or reduced level gas, oxidizing gas, or water) may between any of the afore-mentioned levels.
  • the atmosphere may comprise air.
  • the atmosphere may be inert.
  • the atmosphere may be nonreactive.
  • the atmosphere may be non-reactive with the material (e.g., the pre-transformed material deposited in the layer of material (e.g., powder), or the material comprising the 3D object).
  • the atmosphere may prevent oxidation of the generated 3D object.
  • the atmosphere may prevent oxidation of the pre-transformed material within the layer of pre-transformed material before its transformation, during its transformation, after its transformation, before its hardening, after its hardening, or any combination thereof.
  • the atmosphere may comprise argon or nitrogen gas.
  • the atmosphere may comprise a Nobel gas.
  • the atmosphere can comprise a gas selected from the group consisting of argon, nitrogen, helium, neon, krypton, xenon, hydrogen, carbon monoxide, and carbon dioxide.
  • the atmosphere may comprise hydrogen gas.
  • the atmosphere may comprise a safe amount of hydrogen gas.
  • the atmosphere may comprise a v/v percent of hydrogen gas of at least about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, or 5%, at ambient pressure (e.g., and ambient temperature).
  • the atmosphere may comprise a v/v percent of hydrogen gas of at most about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, or 5%, at ambient pressure (e.g., and ambient temperature).
  • the atmosphere may comprise any percent of hydrogen between the afore-mentioned percentages of hydrogen gas.
  • the atmosphere may comprise a v/v hydrogen gas percent that is at least able to react with the material (e.g., at ambient temperature and/or at ambient pressure), and at most adhere to the prevalent work-safety standards in the jurisdiction (e.g., hydrogen codes and standards).
  • the material may be the material within the layer of pretransformed material (e.g., powder), the transformed material, the hardened material, or the material within the 3D object.
  • Ambient refers to a condition to which people are generally accustomed.
  • ambient pressure may be 1 atmosphere.
  • Ambient temperature may be a typical temperature to which humans are generally accustomed. For example, from about 15°C to about 30°C, from about -30°C to about 60°C, from about -20°C to about 50°C, from 16°C to about 26°C, from about 20°C to about 25°C.
  • Room temperature may be measured in a confined or in a non-confined space.
  • room temperature can be measured in a room, an office, a factory, a vehicle, a container, or outdoors.
  • the vehicle may be a car, a truck, a bus, an airplane, a space shuttle, a space ship, a ship, a boat, or any other vehicle.
  • Room temperature may represent the small range of temperatures at which the atmosphere feels neither hot nor cold, approximately 24°C. It may denote 20°C,
  • the pre-transformed material is deposited in an enclosure (e.g., a container).
  • Fig. 1 shows an example of a container 123.
  • the container can contain the pre-transformed material (e.g., without spillage; Fig. 1 , 104).
  • the material may be placed in, or inserted to the container.
  • the material may be deposited in, pushed to, sucked into, or lifted to the container.
  • the material may be layered (e.g., spread) in the container.
  • the container may comprise a substrate (e.g., Fig. 1 , 109).
  • the substrate may be situated adjacent to the bottom of the container (e.g., Fig.
  • Bottom may be relative to the gravitational field, or relative to the position of the footprint of the energy beam (e.g., Fig. 1 , 101) on the layer of pre-transformed material as part of a material bed.
  • the footprint of the energy beam may follow a Gaussian bell shape. In some embodiments, the footprint of the energy beam does not follow a Gaussian bell shape.
  • the container may comprise a platform comprising a base (e.g., Fig. 1 , 102).
  • the platform may comprise a substrate.
  • the base may reside adjacent to the substrate.
  • the pre-transformed material may be layered adjacent to a side of the container (e.g., on the bottom of the container).
  • the pre-transformed material may be layered adjacent to the substrate and/or adjacent to the base. Adjacent to may be above. Adjacent to may be directly above, or directly on.
  • the substrate may have one or more seals that enclose the material in a selected area within the container (e.g., Fig. 1 ,
  • the one or more seals may be flexible or non-flexible.
  • the one or more seals may comprise a polymer or a resin.
  • the one or more seals may comprise a round edge or a flat edge.
  • the one or more seals may be bendable or non-bendable.
  • the seals may be stiff.
  • the container may comprise the base.
  • the base may be situated within the container.
  • the container may comprise the platform, which may be situated within the container.
  • the enclosure, container, processing chamber, and/or building module may comprise an optical window or an optical mechanism (e.g., Fig. 1 , 120).
  • An example of an optical window can be seen in Fig. 1 , 115; and Fig. 3, 304.
  • the optical window may allow the energy beam (e.g., 307) to pass through without (e.g., substantial) energetic loss (e.g., 303).
  • Components of Fig. 3 can be disposed relative to gravitational vector 399 pointing to gravitational center G.
  • a ventilator may prevent spatter from accumulating on the surface optical window that is disposed within the enclosure (e.g., within the processing chamber) during the 3D printing.
  • An opening of the ventilator may be situated within the enclosure 116.
  • a portion of the enclosure, that is occupied by the energy beam (e.g., during the 3D printing) can define a processing cone (e.g., Fig. 15, 1530).
  • the processing cone comprise a truncated cone.
  • the processing cone can be the enclosure space that is occupied by a non-reflected energy beam during the (e.g., entire) 3D printing.
  • the processing cone can be the enclosure space that is occupied by an energy beam that is directed towards the material bed during the (e.g., entire) 3D printing. During the 3D printing may comprise during printing of a layer of hardened material.
  • the 3D printer comprises a material dispensing mechanism.
  • the pre-transformed material may be deposited in the enclosure by a material dispensing mechanism (also referred to herein as a layer dispenser, layer forming apparatus, or layer forming device) (e.g., Fig. 1 , 122).
  • the material dispensing mechanism includes one or more material dispensers (also referred to herein as “dispensers”) (e.g., Fig.
  • leveling mechanisms also referred to herein as “levelers”
  • powder removal mechanisms also referred to herein as material “removers”
  • Fig. 1 , 118 The deposited material may be leveled by a leveling operation.
  • the leveling operation may comprise using a powder removal mechanism that does not contact the exposed surface of the material bed (e.g., Fig. 1 , 118).
  • the leveling operation may comprise using a leveling mechanism that contacts the exposed surface of the material bed (e.g., Fig. 1 , 117).
  • the material (e.g., powder) dispensing mechanism may comprise one or more dispensers (e.g., Fig. 1 , 116).
  • the material dispensing system may comprise at least one material (e.g., bulk) reservoir.
  • the material may be deposited by a layer dispensing mechanism (e.g., recoater).
  • the layer dispensing mechanism may level the dispensed material without contacting the material bed (e.g., the top surface of the powder bed).
  • the layer dispensing mechanism may include any layer dispensing mechanism and/or a material (e.g., powder) dispenser used in 3D printing such as, for example, the ones disclosed in international patent application number PCT/US15/36802 titled “APPARATUSES,
  • the FLS e.g., width, depth, and/or height
  • the FLS can be at least about 50 millimeters (mm), 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 250 mm, 280 mm, 400 mm, 500 mm, 600mm, 800 mm, 900 mm, 1 meter (m), 2 m or 5 m.
  • the FLS (e.g., width, depth, and/or height) of the material bed can be at most about 50 millimeters (mm), 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 250 mm, 280 mm, 400 mm, 500 mm, 600mm, 800 mm, 900 mm, 1 meter (m), 2 m or 5 m.
  • the FLS of the material bed can be between any of the afore-mentioned values (e.g., from about 50 mm to about 5m, from about 250 mm to about 500 mm, from about 280 mm to about 1 m, or from about 500mm to about 5m).
  • the FLS of the material bed is in the direction of the gas flow.
  • the layer dispensing mechanism may include components comprising a material dispensing mechanism, material leveling mechanism, material removal mechanism, or any combination or permutation thereof.
  • the layer dispensing mechanism and any of its components may be any layer dispensing mechanism (e.g., used in 3D printing) such as for example, any of the ones described in Patent Application serial number PCT/US15/36802, or in Provisional Patent Application serial number 62/317,070, both of which are entirely incorporated herein by references.
  • the layer dispensing mechanism may reside within an ancillary chamber.
  • the ancillary chamber may be any ancillary chamber such as, for example, the one described in Provisional Patent Application serial number 62/471 ,222 filed March 14, 2017, titled OPERATION OF THREE-DIMENSIONAL PRINTER COMPONENTS”, which is entirely incorporated herein by reference in its entirety.
  • the layer dispenser may be physically secluded from the processing chamber when residing in the ancillary chamber.
  • the ancillary chamber may be connected (e.g., reversibly) to the processing chamber.
  • the ancillary chamber may be connected (e.g., reversibly) to the build module.
  • the ancillary chamber may convey the layer dispensing mechanism adjacent to a platform (e.g., that is disposed within the build module).
  • the layer dispensing mechanism may be retracted into the ancillary chamber (e.g., when the layer dispensing mechanism does not perform dispensing).
  • the 3D printer comprises a platform.
  • the platform (also herein, “printing platform” or “building platform”) may be disposed in the enclosure (e.g., in the build module and/or processing chamber).
  • the platform may be configured to support the material bed.
  • the platform may be configured to support multiple layers of pretransformed material (e.g., as part of the material bed).
  • the platform may be configured to support at least a portion of the 3D object (e.g., during forming of the 3D object).
  • the platform may comprise a substrate or a base.
  • the substrate and/or the base may be removable or non-removable.
  • the building platform may be (e.g., substantially) horizontal, (e.g., substantially) planar, or non-planar.
  • the platform may have a surface that points towards the deposited pre-transformed material (e.g., powder material), which at times may point towards the top of the enclosure (e.g., away from the center of gravity).
  • the platform may have a surface that points away from the deposited pre-transformed material (e.g., towards the center of gravity), which at times may point towards the bottom of the container.
  • the platform may have a surface that is (e.g., substantially) flat and/or planar.
  • the platform may have a surface that is not flat and/or not planar.
  • the platform may have a surface that comprises protrusions or indentations.
  • the platform may have a surface that comprises embossing.
  • the platform may have a surface that comprises supporting features (e.g., auxiliary support).
  • the platform may have a surface that comprises a mold.
  • the platform may have a surface that comprises a wave formation.
  • the surface may point towards the layer of pre-transformed material within the material bed.
  • the wave may have an amplitude (e.g., vertical amplitude or at an angle).
  • the platform e.g., base
  • the platform may comprise a mesh through which the pre-transformed material (e.g., the remainder) is able to flow through.
  • the platform may comprise a motor.
  • the platform e.g., substrate and/or base
  • the platform may be fastened to the container.
  • the platform (or any of its components) may be transportable.
  • the transportation of the platform may be controlled and/or regulated by a controller (e.g., control system).
  • the platform may be transportable horizontally, vertically, or at an angle (e.g., planar or compound).
  • the platform is transferable (e.g., translatable).
  • the platform may be vertically transferable, for example using an actuator.
  • the actuator may cause a vertical translation (e.g., and elevator).
  • An actuator causing a vertical translation (e.g., an elevation mechanism) is shown as an example in Fig. 1 , 105.
  • the up and down arrow next to the elevation mechanism 105 signifies a possible direction of movement of the elevation mechanism, or a possible direction of movement effectuated by the elevation mechanism.
  • auxiliary support(s) adhere to the upper surface of the platform.
  • the auxiliary supports of the printed 3D object may touch the platform (e.g., the bottom of the enclosure, the substrate, or the base). Sometimes, the auxiliary support may adhere to the platform. In some embodiments, the auxiliary supports are an integral part of the platform. At times, auxiliary support(s) of the printed 3D object, do not touch the platform. In any of the methods described herein, the printed 3D object may be supported only by the pre-transformed material within the material bed (e.g., powder bed,
  • Any auxiliary support(s) of the printed 3D object, if present, may be suspended adjacent to the platform.
  • the platform may have a pre-hardened (e.g., presolidified) amount of material.
  • Such pre-solidified material may provide support to the printed 3D object.
  • the platform may provide adherence to the material.
  • the platform does not provide adherence to the material.
  • the platform may comprise elemental metal, metal alloy, elemental carbon, or ceramic.
  • the platform may comprise a composite material (e.g., as disclosed herein).
  • the platform may comprise glass, stone, zeolite, or a polymeric material.
  • the polymeric material may include a hydrocarbon or fluorocarbon.
  • the platform may include Teflon.
  • the platform may include compartments for printing small objects. Small may be relative to the size of the enclosure.
  • the compartments may form a smaller compartment within the enclosure, which may accommodate a layer of pretransformed material.
  • the 3D printer comprises an energy source that generates an energy beam.
  • the energy beam may project energy to the material bed.
  • the apparatuses, systems, and/or methods described herein can comprise at least one energy beam. In some cases, the apparatuses, systems, and/or methods described can comprise two, three, four, five, or more energy beams.
  • the energy beam may include radiation comprising electromagnetic, electron, positron, proton, plasma, or ionic radiation.
  • the electromagnetic beam may comprise microwave, infrared, ultraviolet or visible radiation.
  • the ion beam may include a cation or an anion.
  • the electromagnetic beam may comprise a laser beam.
  • the energy beam may derive from a laser source.
  • the energy source (e.g., Fig. 1 , 121 ) may be a laser source.
  • the laser may comprise a fiber laser, a solid-state laser or a diode laser.
  • the energy source is a laser source.
  • the laser source may comprise a Nd: YAG, Neodymium (e.g., neodymium-glass), or an Ytterbium laser.
  • the laser may comprise a carbon dioxide laser (CO2 laser).
  • the laser may be a fiber laser.
  • the laser may be a solid-state laser.
  • the laser can be a diode laser.
  • the energy source may comprise a diode array.
  • the energy source may comprise a diode array laser.
  • the laser may be a laser used for micro laser sintering.
  • the energy beam may be any energy beam disclosed in Provisional Patent Application serial number 62/317,070 that is entirely incorporated herein by reference.
  • the energy beam (e.g., transforming energy beam) comprises a Gaussian energy beam.
  • the energy beam may have any cross-sectional shape comprising an ellipse (e.g., circle), or a polygon (e.g., as disclosed herein).
  • the energy beam may have a cross section with a FLS (e.g., diameter) of at least about 50 micrometers (pm), 100 pm, 150 pm, 200pm, or 250 pm.
  • the energy beam may have a cross section with a FLS of at most about 60 micrometers (pm), 100 pm, 150 pm, 200 pm, or 250 pm.
  • the energy beam cross section may be measured at full width half maximum.
  • the energy beam may have a cross section with a FLS of any value between the afore-mentioned values (e.g., from about 50 pm to about 250 pm, from about 50 pm to about 150 pm, or from about 150 pm to about 250 pm).
  • the power per unit area of the energy beam may be at least about 100 Watt per millimeter square (W/mm 2 ), 200 W/mm 2 , 300 W/mm 2 , 400 W/mm 2 , 500 W/mm 2 , 600 W/mm 2 , 700 W/mm 2 , 800 W/mm 2 , 900 W/mm 2 , 1000 W/mm 2 , 2000 W/mm 2 , 3000 W/mm 2 , 5000 W/mm 2 , 7000 W/mm 2 , or 10000 W/mm 2 .
  • the power per unit area of the tiling energy flux may be at most about 110 W/mm 2 , 200 W/mm 2 , 300 W/mm 2 , 400 W/mm 2 , 500 W/mm 2 , 600 W/mm 2 , 700 W/mm 2 , 800 W/mm 2 , 900 W/mm 2 , 1000 W/mm 2 , 2000 W/mm 2 , 3000 W/mm 2 , 5000 W/mm 2 , 7000 W/mm 2 , or 10000 W/mm 2 .
  • the power per unit area of the energy beam may be any value between the afore-mentioned values (e.g., from about 100 W/mm 2 to about 3000 W/mm 2 , from about 100 W/mm 2 to about 5000 W/mm 2 , from about 100 W/mm 2 to about 10000 W/mm 2 , from about 100 W/mm 2 to about 500 W/mm 2 , from about 1000 W/mm 2 to about 3000 W/mm 2 , from about 1000 W/mm 2 to about 3000 W/mm 2 , or from about 500 W/mm 2 to about 1000 W/mm 2 ).
  • the afore-mentioned values e.g., from about 100 W/mm 2 to about 3000 W/mm 2 , from about 100 W/mm 2 to about 5000 W/mm 2 , from about 100 W/mm 2 to about 10000 W/mm 2 , from about 100 W/mm 2 to about 500 W/mm 2 , from about 1000 W/mm 2 to about 3000 W/mm 2 , from about
  • the scanning speed of the energy beam may be at least about 50 millimeters per second (mm/sec), 100 mm/sec, 500 mm/sec, 1000 mm/sec, 2000 mm/sec, 3000 mm/sec, 4000 mm/sec, or 50000 mm/sec.
  • the scanning speed of the energy beam may be at most about 50 mm/sec, 100 mm/sec, 500 mm/sec, 1000 mm/sec, 2000 mm/sec, 3000 mm/sec, 4000 mm/sec, or 50000 mm/sec.
  • the scanning speed of the energy beam may any value between the afore-mentioned values (e.g., from about 50 mm/sec to about 50000 mm/sec, from about 50 mm/sec to about 3000 mm/sec, or from about 2000 mm/sec to about 50000 mm/sec).
  • the energy beam may be continuous or non-continuous (e.g., pulsing).
  • the energy beam may be modulated before and/or during the formation of a transformed material as part of the 3D object.
  • the energy beam may be modulated before and/or during the 3D printing process.
  • the energy source (e.g., laser) has a power of at least about 10 Watt (W), 30W, 50W, 80W, 100W, 120W, 150W, 200W, 250W, 300W, 350W, 400W, 500W, 750W, 800W, 900W, 1000W, 1500W, 2000W, 3000W, or 4000W.
  • the energy source may have a power of at most about 10 W, 30W, 50W, 80W, 100W, 120W, 150W, 200W, 250W, 300W, 350W, 400W, 500W, 750W, 800W, 900W, 1000W, 1500, 2000W, 3000W, or 4000W.
  • the energy source may have a power between any of the afore-mentioned energy beam power values (e.g., from about 10W to about 100W, from about 100W to about 1000W, or from about 1000W to about 4000W).
  • the energy beam may derive from an electron gun.
  • the energy beam may include a pulsed energy beam, a continuous wave energy beam, or a quasi-continuous wave energy beam.
  • the pulse energy beam may have a repetition frequency of at least about 1 Kilo Hertz (KHz), 2 KHz, 3 KHz, 4 KHz, 5 KHz, 6 KHz, 7 KHz, 8 KHz, 9 KHz, 10 KHz, 20 KHz, 30 KHz, 40 KHz, 50 KHz, 60 KHz, 70 KHz, 80 KHz, 90 KHz, 100 KHz, 150 KHz, 200 KHz, 250 KHz, 300 KHz, 350 KHz, 400 KHz, 450 KHz, 500 KHz, 550 KHz, 600 KHz, 700 KHz, 800 KHz, 900 KHz, 1 Mega Hertz (MHz), 2 MHz, 3 MHz, 4 MHz, or 5 MHz.
  • KHz Kilo Hertz
  • the pulse energy beam may have a repetition frequency of at most about 1 Kilo Hertz (KHz), 2 KHz, 3 KHz, 4 KHz, 5 KHz, 6 KHz, 7 KHz, 8 KHz, 9 KHz, 10 KHz, 20 KHz, 30 KHz, 40 KHz, 50 KHz, 60 KHz, 70 KHz, 80 KHz, 90 KHz, 100 KHz, 150 KHz, 200 KHz, 250 KHz, 300 KHz, 350 KHz, 400 KHz, 450 KHz, 500 KHz, 550 KHz, 600 KHz, 700 KHz, 800 KHz, 900 KHz, 1 Mega Hertz (MHz), 2 MHz, 3 MHz, 4 MHz, or 5 MHz.
  • the pulse energy beam may have a repetition frequency between any of the aforementioned repetition frequencies (e.g., from about 1KHz to about 5MHz, from about 1 KHz to about 1 MHz, or from about 1 MHz to about 5MHz).
  • the methods, apparatuses and/or systems disclosed herein may comprise Q- switching, mode coupling or mode locking to effectuate the pulsing energy beam.
  • the apparatus or systems disclosed herein may comprise an on/off switch, a modulator, or a chopper to effectuate the pulsing energy beam.
  • the on/off switch can be manually or automatically controlled.
  • the switch may be controlled by the control system.
  • the switch may alter the “pumping power” of the energy beam.
  • the energy beam may be at times focused, non-focused, or defocused. In some instances, the defocus is substantially zero (e.g., the beam is non-focused).
  • the energy source(s) projects energy using a DLP modulator, a one-dimensional scanner, a two-dimensional scanner, or any combination thereof.
  • the energy source(s) can be stationary or translatable.
  • the energy source(s) can translate vertically, horizontally, or in an angle (e.g., planar or compound angle).
  • the energy source(s) can be modulated.
  • the energy beam(s) emitted by the energy source(s) can be modulated.
  • the modulator can include an amplitude modulator, phase modulator, or polarization modulator.
  • the modulation may alter the intensity of the energy beam.
  • the modulation may alter the current supplied to the energy source (e.g., direct modulation).
  • the modulation may affect the energy beam (e.g., external modulation such as external light modulator).
  • the modulation may include direct modulation (e.g., by a modulator).
  • the modulation may include an external modulator.
  • the modulator can include an aucusto-optic modulator or an electro-optic modulator.
  • the modulator can comprise an absorptive modulator or a refractive modulator.
  • the modulation may alter the absorption coefficient the material that is used to modulate the energy beam.
  • the modulator may alter the refractive index of the material that is used to modulate the energy beam.
  • the energy beam(s), energy source(s), and/or the platform of the energy beam array is moved.
  • the energy beam(s), energy source(s), and/or the platform of the energy beam array can be moved via a galvanometer scanner (e.g., moving the energy beam(s)), a polygon, a mechanical stage (e.g., X-Y stage), a piezoelectric device, gimble, or any combination of thereof.
  • the galvanometer may comprise a mirror.
  • the galvanometer scanner may comprise a two-axis galvanometer scanner.
  • the scanner may comprise a modulator (e.g., as described herein).
  • the scanner may comprise a polygonal mirror.
  • the scanner can be the same scanner for two or more energy sources and/or beams. At least two (e.g., each) energy source and/or beam may have a separate scanner.
  • the energy sources can be translated independently of each other. In some cases, at least two energy sources and/or beams can be translated at different rates, and/or along different paths. For example, the movement of a first energy source may be faster as compared to the movement of a second energy source.
  • the systems and/or apparatuses disclosed herein may comprise one or more shutters (e.g., safety shutters), on/off switches, or apertures.
  • the energy beam (e.g., laser) has a FLS (e.g., a diameter) of its footprint on the exposed surface of the material bed of at least about 1 micrometer (pm), 5pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 200 pm, 300 pm, 400 pm, or 500 pm.
  • the energy beam may have a FLS on the layer of it footprint on the exposed surface of the material bed of at most about 1 pm, 5pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 200 pm, 300 pm, 400 pm, or 500 pm.
  • the energy beam may have a FLS on the exposed surface of the material bed (e.g., Fig. 3, 302) between any of the afore-mentioned energy beam FLS values (e.g., from about 5 pm to about 500 pm, from about 5 pm to about 50 pm, or from about 50 pm to about 500 pm).
  • the beam may be a focused beam.
  • the beam may be a dispersed beam.
  • the beam may be an aligned beam.
  • the apparatus and/or systems described herein may further comprise a focusing coil, a deflection coil, or an energy beam power supply.
  • the defocused energy beam may have a FLS of at least about 1 mm, 5mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, or 100 mm.
  • the defocused energy beam may have a FLS of at most about 1 mm, 5mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, or 100 mm.
  • the energy beam may have a defocused cross-sectional FLS on the layer of pre-transformed material between any of the afore-mentioned energy beam FLS values (e.g., from about 5 mm to about 100mm, from about 5 mm to about 50 mm, or from about 50 mm to about 100 mm).
  • the 3D printer comprises a power supply.
  • the power supply to any of the components described herein can be supplied by a grid, generator, local, or any combination thereof.
  • the power supply can be from renewable or non-renewable sources.
  • the renewable sources may comprise solar, wind, hydroelectric, or biofuel.
  • the powder supply can comprise rechargeable batteries.
  • the exposure time of the energy beam is at least 1 microsecond (ps), 5ps, 10 ps, 20 ps, 30 ps, 40 ps, 50 ps, 60 ps, 70 ps, 80 ps, 90 ps, 100 ps, 200 ps, 300 ps, 400 ps, 500 ps, 800ps, or 1000ps.
  • the exposure time of the energy beam may be most about 1 ps, 5ps, 10 ps, 20 ps, 30 ps, 40 ps, 50 ps, 60 ps, 70 ps, 80 ps, 90 ps, 100 ps, 200 ps, 300 ps, 400 ps, 500 ps, 800ps, or 1000ps.
  • the exposure time of the energy beam may be any value between the afore-mentioned exposure time values (e.g., from about 1 ps to about 1000 ps, from about 1 ps to about 200 ps, from about 1 ps to about 500 ps, from about 200 ps to about 500 ps, or from about 500 ps to about 1000 ps).
  • the 3D printer comprises at least one controller.
  • the controller may control one or more characteristics of the energy beam (e.g., variable characteristics).
  • the control of the energy beam may allow a low degree of material evaporation during the 3D printing process.
  • controlling on or more energy beam characteristics may (e.g., substantially) reduce the amount of spatter generated during the 3D printing process.
  • the low degree of material evaporation may be measured in grams of evaporated material and compared to a Kilogram of hardened material formed as part of the 3D object.
  • the low degree of material evaporation may be evaporation of at most about 0.25 grams (gr.), 0.5gr, 1 gr, 2gr, 5gr, 10gr, 15gr, 20gr, 30gr, or 50gr per every Kilogram of hardened material formed as part of the 3D object.
  • the low degree of material evaporation per every Kilogram of hardened material formed as part of the 3D object may be any value between the afore-mentioned values (e.g., from about 0.25gr to about 50gr, from about 0.25gr to about 30gr, from about 0.25gr to about 10 gr, from about 0.25gr to about 5gr, or from about 0.25gr to about 2gr).
  • the methods, systems and/or the apparatus described herein can further comprise at least one energy source.
  • the system can comprise two, three, four, five, or more energy sources.
  • An energy source can be a source configured to deliver energy to an area (e.g., a confined area).
  • An energy source can deliver energy to the confined area through radiative heat transfer.
  • the energy source supplies any of the energies described herein (e.g., energy beams).
  • the energy source may deliver energy to a point or to an area.
  • the energy source may include an electron gun source.
  • the energy source may include a laser source.
  • the energy source may comprise an array of lasers.
  • a laser can provide light energy at a peak wavelength of at least about 100 nanometer (nm), 500 nm, 1000 nm, 1010 nm, 1020nm, 1030 nm, 1040 nm, 1050 nm, 1060 nm, 1070 nm, 1080 nm, 1090 nm, 1100 nm, 1200 nm, 1500 nm, 1600 nm, 1700 nm, 1800 nm, 1900 nm, or 2000 nm.
  • nm nanometer
  • a laser can provide light energy at a peak wavelength of at most about 100 nanometer (nm), 500 nm, 1000 nm, 1010 nm, 1020nm, 1030 nm, 1040 nm, 1050 nm,
  • a laser can provide light energy at a peak wavelength between the afore-mentioned peak wavelengths (e.g., from 100nm to 2000 nm, from 10Onm to 110Onm, or from 1000 nm to 2000 nm).
  • the energy beam can be incident on the top surface of the material bed.
  • the energy beam can be incident on, or be directed to, a specified area of the material bed over a specified time period.
  • the energy beam can be substantially perpendicular to the top (e.g., exposed) surface of the material bed.
  • the material bed can absorb the energy from the energy beam (e.g., incident energy beam) and, as a result, a localized region of the material in the material bed can increase in temperature.
  • the increase in temperature may transform the material within the material bed.
  • the increase in temperature may heat and transform the material within the material bed.
  • the increase in temperature may heat and not transform the material within the material bed.
  • the increase in temperature may heat the material within the material bed.
  • the energy beam and/or source is moveable.
  • the energy beam and/or source can be moveable such that it can translate relative to the material bed.
  • the energy beam and/or source can be moved by a scanner.
  • the movement of the energy beam and/or source can comprise utilization of a scanner.
  • the energy source is stationary.
  • At least two of the energy beams and/or sources can be translated independently of each other or in concert with each other. At least two of the multiplicity of energy beams can be translated independently of each other or in concert with each other. In some cases, at least two of the energy beams can be translated at different rates such that the movement of the one is faster compared to the movement of at least one other energy beam. In some cases, at least two of the energy sources can be translated at different rates such that the movement of the one energy source is faster compared to the movement of at least another energy source. In some cases, at least two of the energy sources (e.g., all of the energy sources) can be translated at different paths.
  • At least two of the energy sources can be translated at substantially identical paths. In some cases, at least two of the energy sources can follow one another in time and/or space. In some cases, at least two of the energy sources translate substantially parallel to each other in time and/or space.
  • the power per unit area of at least two of the energy beam may be (e.g., substantially) identical.
  • the power per unit area of at least one of the energy beams may be varied (e.g., during the formation of the 3D object).
  • the power per unit area of at least one of the energy beams may be different.
  • the power per unit area of at least one of the energy beams may be different.
  • the power per unit area of one energy beam may be greater than the power per unit area of a second energy beam.
  • the energy beams may have the same or different wavelengths.
  • a first energy beam may have a wavelength that is smaller or larger than the wavelength of a second energy beam.
  • the energy beams can derive from the same energy source.
  • At least one of the energy beams can derive from different energy sources.
  • the energy beams can derive from different energy sources.
  • At least two of the energy beams may have the same power (e.g., at one point in time, and/or (e.g., substantially) during the entire build of the 3D object).
  • At least one of the beams may have a different power (e.g., at one point in time, and/or substantially during the entire build of the 3D object).
  • the beams may have different powers (e.g., at one point in time, and/or (e.g., substantially) during the entire build of the 3D object). At least two of the energy beams may travel at (e.g., substantially) the same velocity. At least one of the energy beams may travel at different velocities. The velocity of travel (e.g., speed) of at least two energy beams may be (e.g., substantially) constant. The velocity of travel of at least two energy beams may be varied (e.g., during the formation of the 3D object or a portion thereof).
  • the travel may refer to a travel relative to (e.g., on) the exposed surface of the material bed (e.g., powder material). The travel may refer to a travel close to the exposed surface of the material bed. The travel may be within the material bed.
  • the at least one energy beam and/or source may travel relative to the material bed.
  • the energy travels in a path.
  • the path may comprise a hatch.
  • the path of the energy beam may comprise repeating a path.
  • the first energy may repeat its own path.
  • the second energy may repeat its own path, or the path of the first energy.
  • the repetition may comprise a repetition of 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10 times or more.
  • the energy may follow a path comprising parallel lines.
  • Fig. 6, 615 or 614 show paths that comprise parallel lines.
  • the lines may be hatch lines.
  • the distance between each of the parallel lines or hatch lines may be at least about 1 pm, 5pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, or more.
  • the distance between each of the parallel lines or hatch lines may be at most about 1 pm, 5pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, or less.
  • the distance between each of the parallel lines or hatch lines may be any value between any of the aforementioned distance values (e.g., from about 1 pm to about 90 pm, from about 1 pm to about 50 pm, or from about 40 pm to about 90 pm).
  • the distance between the parallel or parallel lines or hatch lines may be substantially the same in every layer (e.g., plane) of transformed material.
  • the distance between the parallel lines or hatch lines in one layer (e.g., plane) of transformed material may be different than the distance between the parallel lines or hatch lines respectively in another layer (e.g., plane) of transformed material within the 3D object.
  • the distance between the parallel lines or hatch lines portions within a layer (e.g., plane) of transformed material may be substantially constant.
  • the distance between the parallel lines or hatch lines within a layer (e.g., plane) of transformed material may be varied.
  • the distance between a first pair of parallel lines or hatch lines within a layer (e.g., plane) of transformed material may be different than the distance between a second pair of parallel lines or hatch lines within a layer (e.g., plane) of transformed material respectively.
  • the first energy beam may follow a path comprising two hatch lines or paths that cross in at least one point.
  • the hatch lines or paths may be straight or curved.
  • the hatch lines or paths may be winding.
  • Fig. 6, 610 or 611 show examples of winding paths.
  • the first energy beam may follow a hatch line or path comprising a U shaped turn (e.g., Fig. 6, 610).
  • the first energy beam may follow a hatch line or path devoid of U shaped turns (e.g., Fig. 612).
  • the formation of the 3D object includes transforming (e.g., fusing, binding or connecting) the pre-transformed material (e.g., powder material) using an energy beam.
  • the energy beam may be projected on to a particular area of the material bed, thus causing the pre-transformed material to transform.
  • the energy beam may cause at least a portion of the pre-transformed material to transform from its present state of matter to a different state of matter.
  • the pre-transformed material may transform at least in part (e.g., completely) from a solid to a liquid state.
  • the energy beam may cause at least a portion of the pre-transformed material to chemically transform.
  • the energy beam may cause chemical bonds to form or break.
  • the chemical transformation may be an isomeric transformation.
  • the transformation may comprise a magnetic transformation or an electronic transformation.
  • the transformation may comprise coagulation of the material, cohesion of the material, or accumulation of the material.
  • the methods described herein may further comprise repeating the operations of material deposition and material transformation operations to produce a 3D object (or a portion thereof) by at least one 3D printing (e.g., additive manufacturing) method.
  • the methods described herein may further comprise repeating the operations of depositing a layer of pre-transformed material and transforming at least a portion of the pretransformed material to connect to the previously formed 3D object portion (e.g., repeating the 3D printing cycle), thus forming at least a portion of a 3D object.
  • the transforming operation may comprise utilizing an energy beam to transform the material.
  • the energy beam is utilized to transform at least a portion of the material bed (e.g., utilizing any of the methods described herein).
  • the transforming energy is provided by an energy source.
  • the transforming energy may comprise an energy beam.
  • the energy source can produce an energy beam.
  • the energy beam may include a radiation comprising electromagnetic, electron, positron, proton, plasma, or ionic radiation.
  • the electromagnetic beam may comprise microwave, infrared, ultraviolet, or visible radiation.
  • the ion beam may include a charged particle beam.
  • the ion beam may include a cation, or an anion.
  • the electromagnetic beam may comprise a laser beam.
  • the laser may comprise a fiber, or a solid-state laser beam.
  • the energy source may include a laser.
  • the energy source may include an electron gun.
  • the energy depletion may comprise heat depletion.
  • the energy depletion may comprise cooling.
  • the energy may comprise an energy flux (e.g., energy beam. E.g., radiated energy).
  • the energy may comprise an energy beam.
  • the energy may be the transforming energy.
  • the energy may be a warming energy that is not able to transform the deposited pre-transformed material (e.g., in the material bed).
  • the warming energy may be able to raise the temperature of the deposited pre-transformed material.
  • the energy beam may comprise energy provided at a (e.g., substantially) constant or varied energy beam characteristics.
  • the energy beam may comprise energy provided at (e.g., substantially) constant or varied energy beam characteristics, depending on the position of the generated hardened material within the 3D object.
  • the varied energy beam characteristics may comprise energy flux, rate, intensity, wavelength, amplitude, power, cross-section, or time exerted for the energy process (e.g., transforming or heating).
  • the energy beam footprint may be the average (or mean) FLS of the foot print of the energy beam on the exposed surface of the material bed.
  • the FLS may be a diameter, a spherical equivalent diameter, a length, a height, a width, or diameter of a bounding circle.
  • the FLS may be the larger of a length, a height, and a width of a 3D form.
  • the energy beam follows a path.
  • the path of the energy beam may be a vector.
  • the path of the energy beam may comprise a raster, a vector, or any combination thereof.
  • the path of the energy beam may comprise an oscillating pattern.
  • the path of the energy beam may comprise a zigzag, wave (e.g., curved, triangular, or square), or curve pattern.
  • the curved wave may comprise a sine or cosine wave.
  • the path of the energy beam may comprise a sub-pattern.
  • the path of the energy beam may comprise an oscillating (e.g., zigzag), wave (e.g., curved, triangular, or square), and/or curved subpattern.
  • the curved wave may comprise a sine or cosine wave.
  • Fig. 5 shows an example of a path 501 of an energy beam comprising a zigzag sub-pattern (e.g., 502 shown as an expansion (e.g., blow-up) of a portion of the path 501).
  • the sub-path of the energy beam may comprise a wave (e.g., sine or cosine wave) pattern.
  • the sub-path may be a small path that forms the large path.
  • the sub-path may be a component (e.g., a portion) of the large path.
  • the path that the energy beam follows may be a predetermined path.
  • a model may predetermine the path by utilizing a controller or an individual (e.g., human).
  • the controller may comprise a processor.
  • the processor may comprise a computer, computer program, drawing or drawing data, statue or statue data, or any combination thereof.
  • the path comprises successive lines.
  • the successive lines may touch each other.
  • the successive lines may overlap each other in at least one point.
  • the successive lines may substantially overlap each other.
  • the successive lines may be spaced by a first distance (e.g., hatch spacing).
  • Fig. 6 shows an example of a path 614 that includes five hatches wherein each two immediately adjacent hatches are separated by a spacing distance.
  • the hatch spacing may be any hatch spacing disclosed in Patent Application serial number PCT/US16/34857 filed on May 27, 2016, titled “THREE- DIMENSIONAL PRINTING AND THREE-DIMENSIONAL OBJECTS FORMED USING THE SAME” that is entirely incorporated herein by reference.
  • auxiliary support generally refers to at least one feature that is a part of a printed 3D object, but not part of the desired, intended, designed, ordered, and/or final 3D object.
  • Auxiliary support may provide structural support during and/or subsequent to the formation of the 3D object.
  • the auxiliary support may be anchored to the enclosure.
  • an auxiliary support may be anchored to the platform (e.g., building platform), to the side walls of the material bed, to a wall of the enclosure, to an object (e.g., stationary or semi-stationary) within the enclosure, or any combination thereof.
  • the auxiliary support may be the platform (e.g., the base, the substrate, or the bottom of the enclosure).
  • the auxiliary support may enable the removal or energy from the 3D object (e.g., or a portion thereof) that is being formed.
  • the removal of energy e.g., heat
  • Examples of auxiliary support comprise a fin (e.g., heat fin), anchor, handle, pillar, column, frame, footing, wall, platform, or another stabilization feature.
  • the auxiliary support may be mounted, clamped, or situated on the platform.
  • the auxiliary support can be anchored to the building platform, to the sides (e.g., walls) of the building platform, to the enclosure, to an object (stationary or semi-stationary) within the enclosure, or any combination thereof.
  • the generated 3D object can be printed without auxiliary support.
  • overhanging feature of the generated 3D object can be printed without (e.g., without any) auxiliary support.
  • the generated object can be devoid of auxiliary supports.
  • the generated object may be suspended (e.g., float anchorlessly) in the material bed (e.g., powder bed).
  • the term “anchorlessly,” as used herein, generally refers to without or in the absence of an anchor.
  • an object is suspended in a powder bed anchorlessly without attachment to a support. For example, the object floats in the powder bed.
  • the generated 3D object may be suspended in the layer of pre-transformed material (e.g., powder material).
  • the pre-transformed material can offer support to the printed 3D object (or the object during its generation).
  • the generated 3D object may comprise one or more auxiliary supports.
  • the auxiliary support may be suspended in the pre-transformed material (e.g., powder material).
  • the auxiliary support may provide weights or stabilizers.
  • the auxiliary support can be suspended in the material bed within the layer of pre-transformed material in which the 3D object (or a portion thereof) has been formed.
  • the auxiliary support (e.g., one or more auxiliary supports) can be suspended in the pre-transformed material within a layer of pre-transformed material other than the one in which the 3D object (or a portion thereof) has been formed (e.g., a previously deposited layer of (e.g., powder) material).
  • the auxiliary support may touch the platform.
  • the auxiliary support may be suspended in the material bed (e.g., powder material) and not touch the platform.
  • the auxiliary support may be anchored to the platform.
  • the distance between any two auxiliary supports can be at least about 1 millimeter, 1 .3 millimeters (mm),
  • any two auxiliary supports can be at most 1 millimeter, 1 .3 mm, 1 .5 mm, 1.8 mm,
  • auxiliary supports can be any value in between the afore-mentioned distances (e.g., from about 1 mm to about 45mm, from about 1 mm to about 11 mm, from about 2.2mm to about 15mm, or from about 10mm to about 45mm).
  • a sphere intersecting an exposed surface of the 3D object may be devoid of auxiliary support.
  • the sphere may have a radius XY that is equal to the distance between any two auxiliary supports mentioned herein.
  • the diminished number of auxiliary supports or lack of auxiliary support may facilitate a 3D printing process that requires a smaller amount of material, produces a smaller amount of material waste, and/or requires smaller energy as compared to commercially available 3D printing processes.
  • the reduced number of auxiliary supports can be smaller by at least about 1.1 , 1.3, 1.5, 2, 3, 4, 5, 6, 7, 8, 9, or 10 as compared to conventional 3D printing.
  • the smaller amount may be smaller by any value between the aforesaid values (e.g., from about 1 .1 to about 10, or from about 1.5 to about 5) as compared to conventional 3D printing.
  • the generated 3D object has a surface roughness profile.
  • the generated 3D object can have various surface roughness profiles, which may be suitable for various applications.
  • the surface roughness may be the deviations in the direction of the normal vector of a real surface from its ideal form.
  • the generated 3D object can have a Ra value of as disclosed herein.
  • the generated 3D object (e.g., the hardened cover) may be substantially smooth.
  • the generated 3D object may have a deviation from an ideal planar surface (e.g., atomically flat or molecularly flat) of at most about 1 .5 nanometers (nm), 2 nm, 3 nm, 4 nm, 5 nm, 10 nm, 15 nm, 20 nm, 25 nm, 30 nm, 35 nm, 100 nm, 300 nm, 500 nm, 1 micrometer (pm), 1 .5 pm, 2 pm, 3 pm, 4 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 100 pm, 300 pm, 500 pm, or less.
  • an ideal planar surface e.g., atomically flat or molecularly flat
  • the generated 3D object may have a deviation from an ideal planar surface of at least about 1.5 nanometers (nm), 2 nm, 3 nm, 4 nm, 5 nm, 10 nm, 15 nm, 20 nm, 25 nm, 30 nm, 35 nm, 100 nm, 300 nm, 500 nm, 1 micrometer (miti), 1 .5 miti, 2 miti, 3 miti, 4 miti, 5 miti, 10 miti, 15 miti, 20 miti, 25 mm, 30 mm, 35 miti, 100 mm, 300 miti, 500 mm, or more.
  • the generated 3D object may have a deviation from an ideal planar surface between any of the afore-mentioned deviation values.
  • the generated 3D object may comprise a pore.
  • the generated 3D object may comprise pores.
  • the pores may be of an average FLS (diameter or diameter equivalent in case the pores are not spherical) of at most about 1.5 nanometers (nm), 2nm, 3nm, 4nm, 5 nm, 10nm, 15nm, 20nm, 25nm, 30nm 35nm, 100nm, 300nm, 500nm, 1 micrometer (pm), 1.5 pm, 2 pm, 3 pm, 4 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 100 pm, 300 pm, or 500 pm.
  • the pores may be of an average FLS of at least about 1 .5 nanometers (nm), 2nm, 3nm, 4nm, 5 nm, 10nm, 15nm, 20nm, 25nm, 30nm, 35nm, 10Onm, 300nm, 500nm, 1 micrometer (pm), 1 .5 pm, 2 pm, 3 pm, 4 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 100 pm, 300 pm, or 500 pm.
  • the pores may be of an average FLS between any of the afore-mentioned FLS values (e.g., from about 1 nm to about 500 pm, or from about 20 pm, to about 300 pm).
  • the 3D object (or at least a layer thereof) may have a porosity of at most about 0.05 percent (%), 0.1% 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1 %, 2 %, 3 %, 4 %, 5 %, 6 %, 7 %, 8 %, 9%, 10 %, 20%, 30%, 40%, 50%, 60%, 70%, or 80%.
  • the 3D object (or at least a layer thereof) may have a porosity of at least about 0.05 %, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1 %, 2 %, 3 %, 4 %, 5 %, 6 %, 7 %, 8 %, 9%, 10 %, 20%, 30%, 40%, 50%, 60%, 70%, or 80%.
  • the 3D object (or at least a layer thereof) may have porosity between any of the afore-mentioned porosity percentages (e.g., from about 0.05% to about 80%, from about 0.05% to about 40%, from about 10% to about 40%, or from about 40% to about 90%).
  • a pore may traverse the generated 3D object.
  • the pore may start at a face of the 3D object and end at the opposing face of the 3D object.
  • the pore may comprise a passageway extending from one face of the 3D object and ending on the opposing face of that 3D object.
  • the pore may not traverse the generated 3D object.
  • the pore may form a cavity in the generated 3D object.
  • the pore may form a cavity on a face of the generated 3D object.
  • pore may start on a face of the plane and not extend to the opposing face of that 3D object.
  • the formed plane comprises a protrusion.
  • the protrusion can be a grain, a bulge, a bump, a ridge, or an elevation.
  • the generated 3D object may comprise protrusions.
  • the protrusions may be of an average FLS of at most about 1.5 nanometers (nm), 2nm, 3nm, 4nm, 5 nm, 10nm, 15nm, 20nm, 25nm, 30nm, 35nm, 100nm, 300nm, 500nm, 1 micrometer (pm), 1.5 pm, 2pm, 3pm, 4pm, 5 pm, 10pm, 15pm, 20pm, 25pm, 30pm, 35pm, 100pm, 300pm, 500pm, or less.
  • the protrusions may be of an average FLS of at least about 1.5 nanometers (nm), 2nm, 3nm, 4nm, 5 nm, 10nm, 15nm, 20nm, 25nm, 30nm, 35nm, 100nm, 300nm, 500nm, 1 micrometer (pm), 1.5 pm, 2pm, 3pm, 4pm, 5 pm, 10pm, 15pm, 20pm, 25pm, 30pm, 35pm, 100pm, 300pm, 500pm, or more.
  • the protrusions may be of an average FLS between any of the afore-mentioned FLS values.
  • the protrusions may constitute at most about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, or 50% of the area of the generated 3D object.
  • the protrusions may constitute at least about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, or 50% of the area of the 3D object.
  • the protrusions may constitute a percentage of an area of the 3D object that is between the afore-mentioned percentages of 3D object area.
  • the protrusion may reside on any surface of the 3D object.
  • the protrusions may reside on an external surface of a 3D object.
  • the protrusions may reside on an internal surface (e.g., a cavity) of a 3D object.
  • the average size of the protrusions and/or of the holes may determine the resolution of the printed (e.g., generated) 3D object.
  • the resolution of the printed 3D object may be at least about 1 micrometer, 1 .3 micrometers (pm), 1 .5 pm, 1 .8 pm, 1 .9 pm, 2.0 pm, 2.2 pm, 2.4 pm, 2.5 pm, 2.6 pm, 2.7 pm, 3 pm, 4 pm, 5 pm, 10 pm, 20 pm, 30 pm,
  • the resolution of the printed 3D object may be at most about 1 micrometer, 1.3 micrometers (pm), 1 .5 pm, 1.8 pm, 1 .9 pm, 2.0 pm, 2.2 pm, 2.4 pm, 2.5 pm, 2.6 pm, 2.7 pm, 3 pm, 4 pm, 5 pm, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 200 pm, or less.
  • the resolution of the printed 3D object may be any value between the above-mentioned resolution values.
  • the 3D object may have a material density of at least about 99.9%, 99.8%, 99.7%, 99.6%, 99.5%, 99.4%, 99.3%, 99.2% 99.1%, 99%, 98%, 96%, 95%, 94%, 93%, 92%, 91%, 90%, 8%, or 70%.
  • the 3D object may have a material density of at most about 99.5%, 99%, 98%, 96%, 95%, 94%, 93%, 92%, 91%, 90%, 8%, or 70%.
  • the 3D object may have a material density between the afore-mentioned material densities.
  • the resolution of the 3D object may be at least about 100 dots per inch (dpi), 300dpi, 600dpi, 1200dpi, 2400dpi, 3600dpi, or 4800dpi.
  • the resolution of the 3D object may be at most about 100 dpi, 300dpi, 600dpi, 1200dpi, 2400dpi, 3600dpi, or 4800dip.
  • the resolution of the 3D object may be any value between the afore-mentioned values (e.g., from 100dpi to 4800dpi, from 300dpi to 2400dpi, or from 600dpi to 4800dpi).
  • the height uniformity (e.g., deviation from average surface height) of a planar surface of the 3D object may be at least about 100 pm, 90 pm, 80 pm, 70 pm, 60 pm, 50 pm, 40 pm, 30 pm, 20 pm, 10 pm, or 5 pm.
  • the height uniformity of the planar surface may be at most about 100 pm, 90 pm, 80, 70 pm, 60 pm, 50 pm, 40 pm, 30 pm, 20 pm, 10 pm, or 5 pm.
  • the height uniformity of the planar surface of the 3D object may be any value between the afore-mentioned height deviation values (e.g., from about 100 pm to about 5 pm, from about 50 pm to about 5 pm, from about 30 pm to about 5 pm, or from about 20 pm to about 5 pm).
  • the height uniformity may comprise high precision uniformity.
  • the energy is transferred from the material bed to the cooling member.
  • Energy e.g., heat
  • the cooling member e.g., heat sink
  • Fig. 1 , 113 shows an example of a cooling member.
  • the heat transfer mechanism may comprise conduction, radiation, or convection.
  • the convection may comprise natural or forced convection.
  • the cooling member can be solid, liquid, gas, or semi-solid.
  • the cooling member e.g., heat sink
  • the cooling member may be located above, below, or to the side of the powder layer.
  • the cooling member may comprise an energy conductive material.
  • the cooling member may comprise an active energy transfer or a passive energy transfer.
  • the cooling member may comprise a cooling liquid (e.g., aqueous or oil), cooling gas, or cooling solid.
  • the cooling member may be further connected to a cooler and/or a thermostat.
  • the gas, semi-solid, or liquid comprised in the cooling member may be stationary or circulating.
  • the cooling member may comprise a material that conducts heat efficiently.
  • the heat (thermal) conductivity of the cooling member may be at least about 20 Watts per meter times Kelvin (W/mK), 50 W/mK, 100 W/mK, 150 W/mK, 200 W/mK, 205 W/mK, 300 W/mK, 350 W/mK, 400 W/mK, 450 W/mK, 500 W/mK, 550 W/mK, 600 W/mK, 700 W/mK, 800 W/mK, 900 W/mK, or 1000 W/mK.
  • W/mK Kelvin
  • the heat conductivity of the heat sink may be at most about 20 W/mK, 50 W/mK, 100 W/mK, 150 W/mK, 200 W/mK, 205 W/mK, 300 W/mK, 350 W/mK, 400 W/mK, 450 W/mK, 500 W/mK, 550 W/mK, 600 W/mK, 700 W/mK, 800 W/mK, 900 W/mK, or 1000 W/mK.
  • the heat conductivity of the heat sink may any value between the afore-mentioned heat conductivity values.
  • the heat (thermal) conductivity of the cooling member may be measured at ambient temperature (e.g., room temperature) and/or pressure.
  • the heat conductivity may be measured at about 20°C and a pressure of 1 atmosphere.
  • the heat sink can be separated from the powder bed or powder layer by a gap.
  • the gap can be filled with a gas.
  • the cooling member may be any cooling member (e.g., that is used in 3D printing) such as, for example, the ones described in Patent Application serial number PCT/US15/36802, or in Provisional Patent Application serial number 62/317,070, both of which are entirely incorporated herein by references.
  • the material bed reaches a certain (e.g., average) temperature.
  • the average temperature of the material bed can be an ambient temperature or “room temperature.”
  • the average temperature of the material bed can have an average temperature during the operation of the energy (e.g., beam).
  • the average temperature of the material bed can be an average temperature during the formation of the transformed material, the formation of the hardened material, or the generation of the 3D object.
  • the average temperature can be below or just below the transforming temperature of the material. Just below can refer to a temperature that is at most about 1°C, 2°C, 3°C, 4°C, 5°C, 6°C, 7°C, 8°C, 9°C, 10°C, 15°C, or 20°C below the transforming temperature.
  • the average temperature of the material bed can be at most about 10°C (degrees Celsius), 20 °C, 25 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100°C, 120 °C, 140 °C, 150 °C, 160 °C, 180 °C, 200 °C, 250 °C, 300 °C, 400 °C, 500 °C, 600 °C, 700 °C, 800 °C, 900 °C, 1000°C, 1200°C, 1400°C, 1600°C, 1800°C, or 2000 °C.
  • the average temperature of the material bed (e.g., pretransformed material) can be at least about 10°C, 20 °C, 25 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100°C, 120 °C, 140 °C, 150 °C, 160 °C, 180 °C, 200 °C, 250 °C, 300 °C, 400 °C, 500 °C, 600 °C, 700 °C, 800 °C, 900 °C, 1000°C, 1200°C, 1400°C, 1600°C, 1800°C, or 2000 °C.
  • the average temperature of the material bed can be any temperature between the afore-mentioned material average temperatures.
  • the average temperature of the material bed (e.g., pre-transformed material) may refer to the average temperature during the 3D printing.
  • the pre-transformed material can be the material within the material bed that has not been transformed and generated at least a portion of the 3D object (e.g., the remainder).
  • the material bed can be heated or cooled before, during, or after forming the 3D object (e.g., hardened material).
  • Bulk heaters can heat the material bed.
  • the bulk heaters can be situated adjacent to (e.g., above, below, or to the side of) the material bed, or within a material dispensing system.
  • the material can be heated using radiators (e.g., quartz radiators, or infrared emitters).
  • the material bed temperature can be substantially maintained at a predetermined value.
  • the temperature of the material bed can be monitored.
  • the material temperature can be controlled manually and/or by a control system.
  • the pre-transformed material is heated.
  • the pre-transformed material within the material bed can be heated by a first energy source such that the heating will transform the pre-transformed material.
  • the remainder of the material that did not transform to generate at least a portion of the 3D object e.g., the remainder
  • the remainder can be heated by a second energy source.
  • the remainder can be at an average temperature that is less than the liquefying temperature of the material (e.g., during the 3D printing).
  • the maximum temperature of the transformed portion of the material bed and the average temperature of the remainder of the material bed can be different.
  • the solidus temperature of the material can be a temperature wherein the material is in a solid state at a given pressure (e.g., ambient pressure). Ambient may refer to the surrounding.
  • the liquefying temperature can be at least about 100 ° C, 200 ° C, 300 ° C, 400 ° C, or 500 ° C
  • the solidus temperature can be at most about 500 ° C, 400 ° C, 300 ° C, 200 ° C, or 100 ° C.
  • the liquefying temperature is at least about 300 ° C and the solidus temperature is less than about 300 ° C.
  • the liquefying temperature is at least about 400 ° C and the solidus temperature is less than about 400 ° C.
  • the liquefying temperature may be different from the solidus temperature.
  • the temperature of the pre-transformed material is maintained above the solidus temperature of the material and below its liquefying temperature.
  • the material from which the pre-transformed material is composed has a super cooling temperature (or super cooling temperature regime).
  • the molten material will remain molten as the material bed is held at or above the material super cooling temperature of the material, but below its melting point.
  • the materials may form a eutectic material on transformation of the material.
  • the liquefying temperature of the formed eutectic material may be the temperature at the eutectic point, close to the eutectic point, or far from the eutectic point. Close to the eutectic point may designate a temperature that is different from the eutectic temperature (e.g., temperature at the eutectic point) by at most about 0.1 °C, 0.5°C, 1°C, 2°C, 4°C, 5°C, 6°C, 8°C, 10°C, or 15°C.
  • a temperature that is farther from the eutectic point than the temperature close to the eutectic point is designated herein as a temperature far from the eutectic Point.
  • the process of liquefying and solidifying a portion of the material can be repeated until the entire object has been formed. At the completion of the generated 3D object, it can be removed from the remainder of material in the container. The remaining material can be separated from the portion at the generated 3D object.
  • the generated 3D object can be hardened and removed from the container (e.g., from the substrate or from the base).
  • the methods described herein may further comprise stabilizing the temperature within the enclosure. For example, stabilizing the temperature of the atmosphere or the pretransformed material (e.g., within the material bed). Stabilization of the temperature may be to a predetermined temperature value.
  • the methods described herein may further comprise altering the temperature within at least one portion of the container. Alteration of the temperature may be to a predetermined temperature. Alteration of the temperature may comprise heating and/or cooling the material bed. Elevating the temperature (e.g., of the material bed) may be to a temperature below the temperature at which the pre-transformed material fuses (e.g., melts or sinters), connects, or bonds.
  • the 3D printer comprises an optical system.
  • the apparatus and/or systems described herein may comprise an optical system.
  • the optical components may be controlled manually and/or via a control system (e.g., a controller).
  • the optical system may be configured to direct at least one energy beam (e.g., 307) from the at least one energy source (energy beam source such as shown in Fig. 3, 306) to a position on the material bed within the enclosure (e.g., a predetermined position).
  • a scanner can be included in the optical system.
  • the printing system may comprise a processor (e.g., a central processing unit).
  • the processor can be programmed to control a trajectory of the at least one energy beam and/or energy source with the aid of the optical system.
  • the systems and/or the apparatus described herein can further comprise a control system in communication with the at least one energy source and/or energy beam.
  • the control system can regulate a supply of energy from the at least one energy source to the material in the container.
  • the control system may control the various components of the optical system.
  • the various components of the optical system may include optical components comprising a mirror (e.g., 305), a lens (e.g., concave or convex), a fiber, a beam guide, a rotating polygon, or a prism.
  • the lens may be a focusing or a dispersing lens.
  • the lens may be a diverging or converging lens.
  • the mirror can be a deflection mirror.
  • the optical components may be tiltable and/or rotatable.
  • the optical components may be tilted and/or rotated.
  • the mirror may be a deflection mirror.
  • the optical components may comprise an aperture.
  • the aperture may be mechanical.
  • the optical system may comprise a variable focusing device.
  • the variable focusing device may be connected to the control system.
  • the variable focusing device may be controlled by the control system and/or manually.
  • the variable focusing device may comprise a modulator.
  • the modulator may comprise an acousto-optical modulator, mechanical modulator, or an electro optical modulator.
  • the focusing device may comprise an aperture (e.g., a diaphragm aperture).
  • the container comprises one or more sensors.
  • the container described herein may comprise at least one sensor.
  • the sensor may be connected and/or controlled by the control system (e.g., computer control system, or controller).
  • the control system may be able to receive signals from the at least one sensor.
  • the control system may act upon at least one signal received from the at least one sensor.
  • the control may rely on feedback and/or feed forward mechanisms that has been pre-programmed.
  • the feedback and/or feed forward mechanisms may rely on input from at least one sensor that is connected to the control unit.
  • the senor detects the amount material (e.g., pretransformed material) in the enclosure.
  • the controller may monitor the amount of material in the enclosure (e.g., within the material bed).
  • the systems and/or the apparatus described herein can include a pressure sensor.
  • the pressure sensor may measure the pressure of the chamber (e.g., pressure of the chamber atmosphere).
  • the pressure sensor can be coupled to a control system.
  • the pressure can be electronically and/or manually controlled.
  • the controller may regulate the pressure (e.g., with the aid of one or more vacuum pumps) according to input from at least one pressure sensor.
  • the sensor may comprise light sensor, image sensor, acoustic sensor, vibration sensor, chemical sensor, electrical sensor, magnetic sensor, fluidity sensor, movement sensor, speed sensor, position sensor, pressure sensor, force sensor, density sensor, metrology sensor, sonic sensor (e.g., ultrasonic sensor), or proximity sensor.
  • the metrology sensor may comprise measurement sensor (e.g., height, length, width, depth, angle, and/or volume).
  • the metrology sensor may comprise a magnetic, acceleration, orientation, or optical sensor.
  • the optical sensor may comprise a camera (e.g., IR camera, or CCD camera (e.g., single line CCD camera)) or CCD camera (e.g., single line CCD camera).
  • the sensor may transmit and/or receive sound (e.g., echo), magnetic, electronic, or electromagnetic signal.
  • the electromagnetic signal may comprise a visible, infrared, ultraviolet, ultrasound, radio wave, or microwave signal.
  • the metrology sensor may measure the tile.
  • the metrology sensor may measure the gap.
  • the metrology sensor may measure at least a portion of the layer of material (e.g., pretransformed, transformed, and/or hardened).
  • the layer of material may be a pre-transformed material (e.g., powder), transformed material, or hardened material.
  • the metrology sensor may measure at least a portion of the 3D object.
  • the sensor may comprise a temperature sensor, weight sensor, powder level sensor, gas sensor, or humidity sensor.
  • the gas sensor may sense any gas enumerated herein.
  • the temperature sensor may comprise Bolometer, Bimetallic strip, Calorimeter, Exhaust gas temperature gauge, Flame detection, Gardon gauge, Golay cell, Heat flux sensor, Infrared thermometer, Microbolometer, Microwave radiometer, Net radiometer, Quartz thermometer, Resistance temperature detector, Resistance thermometer, Silicon band gap temperature sensor, Special sensor microwave/imager, Temperature gauge, Thermistor, Thermocouple, Thermometer, Pyrometer, IR camera, or CCD camera (e.g., single line CCD camera).
  • the temperature sensor may measure the temperature without contacting the material bed (e.g., non-contact measurements).
  • the pyrometer may comprise a point pyrometer, or a multi-point pyrometer.
  • the Infrared (IR) thermometer may comprise an IR camera.
  • the pressure sensor may comprise Barograph, Barometer, Boost gauge, Bourdon gauge, hot filament ionization gauge, Ionization gauge, McLeod gauge, Oscillating U-tube, Permanent Downhole Gauge, Piezometer, Pirani gauge, Pressure sensor, Pressure gauge, tactile sensor, or Time pressure gauge.
  • the position sensor may comprise Auxanometer, Capacitive displacement sensor, Capacitive sensing, Free fall sensor, Gravimeter, Gyroscopic sensor, Impact sensor, Inclinometer, Integrated circuit piezoelectric sensor, Laser rangefinder, Laser surface velocimeter, LIDAR, Linear encoder, Linear variable differential transformer (LVDT), Liquid capacitive inclinometers, Odometer, Photoelectric sensor, Piezoelectric accelerometer, Rate sensor, Rotary encoder, Rotary variable differential transformer, Selsyn, Shock detector, Shock data logger, Tilt sensor, Tachometer, Ultrasonic thickness gauge, Variable reluctance sensor, or Velocity receiver.
  • Auxanometer Capacitive displacement sensor, Capacitive sensing, Free fall sensor, Gravimeter, Gyroscopic sensor, Impact sensor, Inclinometer, Integrated circuit piezoelectric sensor, Laser rangefinder, Laser surface velocimeter, LIDAR, Linear encoder, Linear variable differential transformer (LVDT), Liquid capacitive inclinometers, Odometer,
  • the optical sensor may comprise a Charge-coupled device, Colorimeter, Contact image sensor, Electro-optical sensor, Infra-red sensor, Kinetic inductance detector, light emitting diode as light sensor, Light-addressable potentiometric sensor, Nichols radiometer, Fiber optic sensors, optical position sensor, photo detector, photodiode, photomultiplier tubes, phototransistor, photoelectric sensor, photoionization detector, photomultiplier, photo resistor, photo switch, phototube, scintillometer, Shack- Hartmann, single-photon avalanche diode, superconducting nanowire single-photon detector, transition edge sensor, visible light photon counter, or wave front sensor.
  • the weight of the enclosure e.g., container
  • any components within the enclosure can be monitored by at least one weight sensor in or adjacent to the material.
  • a weight sensor can be situated at the bottom of the enclosure.
  • the weight sensor can be situated between the bottom of the enclosure and the substrate.
  • the weight sensor can be situated between the substrate and the base.
  • the weight sensor can be situated between the bottom of the container and the base.
  • the weight sensor can be situated between the bottom of the container and the top of the material bed.
  • the weight sensor can comprise a pressure sensor.
  • the weight sensor may comprise a spring scale, a hydraulic scale, a pneumatic scale, or a balance. At least a portion of the pressure sensor can be exposed on a bottom of the container.
  • the at least one weight sensor can comprise a button load cell.
  • a sensor can be configured to monitor the weight of the material by monitoring a weight of a structure that contains the material (e.g., a material bed).
  • One or more position sensors e.g., height sensors
  • the position sensors can be optical sensors.
  • the position sensors can determine a distance between one or more energy sources and a surface of the material bed.
  • the surface of the material bed can be the upper surface of the material bed.
  • Fig. 1 , 119 shows an example of an upper surface of the material bed 104.
  • the 3D printer comprises one or more valves.
  • the methods, systems and/or the apparatus described herein may comprise at least one valve.
  • the valve may be shut or opened according to an input from the at least one sensor, or manually.
  • the degree of valve opening or shutting may be regulated by the control system, for example, according to at least one input from at least one sensor.
  • the systems and/or the apparatus described herein can include one or more valves, such as throttle valves.
  • the 3D printer comprises one or more motors.
  • the methods, systems and/or the apparatus described herein may comprise a motor.
  • the motor may be controlled by the control system and/or manually.
  • the apparatuses and/or systems described herein may include a system providing the material (e.g., powder material) to the material bed.
  • the system for providing the material may be controlled by the control system, or manually.
  • the motor may connect to a system providing the material (e.g., powder material) to the material bed.
  • the system and/or apparatus of the present invention may comprise a material reservoir.
  • the material may travel from the reservoir to the system and/or apparatus of the present invention may comprise a material reservoir.
  • the material may travel from the reservoir to the system for providing the material to the material bed.
  • the motor may alter (e.g., the position of) the substrate and/or to the base.
  • the motor may alter (e.g., the position of) the elevator.
  • the motor may alter an opening of the enclosure (e.g., its opening or closure).
  • the motor may be a step motor or a servomotor.
  • the methods, systems and/or the apparatus described herein may comprise a piston.
  • the piston may be a trunk, crosshead, slipper, or deflector piston.
  • the 3D printer comprises one or more nozzles.
  • the systems and/or the apparatus described herein may comprise at least one nozzle.
  • the nozzle may be regulated according to at least one input from at least one sensor.
  • the nozzle may be controlled automatically or manually.
  • the controller may control the nozzle.
  • the nozzle may include jet (e.g., gas jet) nozzle, high velocity nozzle, propelling nozzle, magnetic nozzle, spray nozzle, vacuum nozzle, or shaping nozzle (e.g., a die).
  • the nozzle can be a convergent or a divergent nozzle.
  • the spray nozzle may comprise an atomizer nozzle, an air-aspirating nozzle, or a swirl nozzle.
  • the 3D printer comprises one or more pumps.
  • the systems and/or the apparatus described herein may comprise at least one pump.
  • the pump may be regulated according to at least one input from at least one sensor.
  • the pump may be controlled automatically or manually.
  • the controller may control the pump.
  • the one or more pumps may comprise a positive displacement pump.
  • the positive displacement pump may comprise rotary-type positive displacement pump, reciprocating-type positive displacement pump, or linear-type positive displacement pump.
  • the positive displacement pump may comprise rotary lobe pump, progressive cavity pump, rotary gear pump, piston pump, diaphragm pump, screw pump, gear pump, hydraulic pump, rotary vane pump, regenerative (peripheral) pump, peristaltic pump, rope pump or flexible impeller.
  • Rotary positive displacement pump may comprise gear pump, screw pump, or rotary vane pump.
  • the reciprocating pump comprises plunger pump, diaphragm pump, piston pumps displacement pumps, or radial piston pump.
  • the pump may comprise a valve-less pump, steam pump, gravity pump, eductor-jet pump, mixed-flow pump, bellow pump, axial-flow pumps, radial- flow pump, velocity pump, hydraulic ram pump, impulse pump, rope pump, compressed-air- powered double-diaphragm pump, triplex-style plunger pump, plunger pump, peristaltic pump, roots-type pumps, progressing cavity pump, screw pump, or gear pump.
  • the systems and/or the apparatus described herein include one or more vacuum pumps selected from mechanical pumps, rotary vain pumps, turbomolecular pumps, ion pumps, cryopumps, and diffusion pumps.
  • the one or more vacuum pumps may comprise Rotary vane pump, diaphragm pump, liquid ring pump, piston pump, scroll pump, screw pump, Wankel pump, external vane pump, roots blower, multistage Roots pump, Toepler pump, or Lobe pump.
  • the one or more vacuum pumps may comprise momentum transfer pump, regenerative pump, entrapment pump, Venturi vacuum pump, or team ejector.
  • the 3D printer comprises a communication technology.
  • the systems, apparatuses, and/or parts thereof may comprise Bluetooth technology.
  • Systems, apparatuses, and/or parts thereof may comprise a communication port.
  • the communication port may be a serial port or a parallel port.
  • the communication port may be a Universal Serial Bus port (e.g., USB).
  • the systems, apparatuses, and/or parts thereof may comprise USB ports.
  • the USB can be micro or mini USB.
  • the USB port may relate to device classes comprising OOh, 01 h, 02h, 03h, 05h, 06h, 07h, 08h, 09h, OAh, OBh, ODh, OEh, OFh, 10h, 11 h, DCh, EOh, EFh, FEh, or FFh.
  • the surface identification mechanism may comprise a plug and/or a socket (e.g., electrical, AC power, DC power).
  • the systems, apparatuses, and/or parts thereof may comprise an adapter (e.g., AC and/or DC power adapter).
  • the systems, apparatuses, and/or parts thereof may comprise a power connector.
  • the power connector can be an electrical power connector.
  • the power connector may comprise a magnetically attached power connector.
  • the power connector can be a dock connector.
  • the connector can be a data and power connector.
  • the connector may comprise pins.
  • the connector may comprise at least 10, 15, 18, 20, 22, 24, 26, 28, 30, 40, 42, 45,
  • the 3D printer comprises a controller.
  • the controller may monitor and/or direct (e.g., physical) alteration of the operating conditions of the apparatuses, software, and/or methods described herein.
  • the controller may be a manual or a non-manual controller.
  • the controller may be an automatic controller.
  • the controller may operate upon request.
  • the controller may be a programmable controller.
  • the controller may be programed.
  • the controller may comprise a processing unit (e.g., CPU or GPU).
  • the controller may receive an input (e.g., from a sensor).
  • the controller may deliver an output.
  • the controller may comprise multiple controllers.
  • the controller may receive multiple inputs.
  • the controller may generate multiple outputs.
  • the controller may be a single input single output controller (SISO) or a multiple input multiple output controller (MIMO).
  • the controller may interpret the input signal received.
  • the controller may acquire data from the one or more sensors. Acquire may comprise receive or extract.
  • the data may comprise measurement, estimation, determination, generation, or any combination thereof.
  • the controller may comprise feedback control.
  • the controller may comprise feed-forward control.
  • the control may comprise on-off control, proportional control, proportional-integral (PI) control, or proportional-integral-derivative (PID) control.
  • the control may comprise open loop control, or closed loop control.
  • the controller may comprise closed loop control.
  • the controller may comprise open loop control.
  • the controller may comprise a user interface.
  • the user interface may comprise a keyboard, keypad, mouse, touch screen, microphone, speech recognition package, camera, imaging system, or any combination thereof.
  • the outputs may include a display (e.g., screen), speaker, or printer.
  • the controller may be any controller (e.g., a controller used in 3D printing) such as, for example, the controller disclosed in Provisional Patent Application serial number 62/252,330 that was filed on November 6, 2015, titled “APPARATUSES, SYSTEMS AND METHODS FOR THREE- DIMENSIONAL PRINTING,” or in Provisional Patent Application serial number 62/325,402 that was filed on April 20, 2016, titled “METHODS, SYSTEMS, APPARATUSES, AND SOFTWARE FOR ACCURATE THREE-DIMENSIONAL PRINTING,” both of which are incorporated herein by reference in their entirety.
  • Control may comprise regulate, modulate, adjust, maintain, alter, change, govern, manage, restrain, restrict, direct guide, oversee, manage, preserve, sustain, restrain, temper, maintain, or vary.
  • the control may comprise wired and/or wireless communication with one or more controllers (e.g., a hierarchical control system having three or more hierarchical control levels).
  • the one or more controllers may be operatively coupled to one or more components of the 3D printing system.
  • the one or more controllers may comprise a microcontroller.
  • the one or more controllers may comprise a controllers disposed in a facility remote from the facility in which the 3D printing system is disposed. At least one of the controllers may be disposed in the cloud. At least one of the controllers may be disposed in a facility in a facility of the 3D printing manufacturer.
  • the methods, systems, software and/or the apparatuses described herein comprise a control system.
  • the control system can be in communication with one or more energy sources and/or energy (e.g., energy beams).
  • the energy sources may be of the same type or of different types.
  • the energy sources can be both lasers, or a laser and an electron beam.
  • the control system may be in communication with the first energy and/or with the second energy.
  • the control system may regulate the one or more energies (e.g., energy beams).
  • the control system may regulate the energy supplied by the one or more energy sources.
  • the control system may regulate the energy supplied by a first energy beam and by a second energy beam, to the pre-transformed material within the material bed.
  • the control system may regulate the position of the one or more energy beams.
  • the control system may regulate the position of the first energy beam and/or the position of the second energy beam.
  • a plurality of energy beams is used to transform the pretransformed material and for one or more 3D objects.
  • the plurality of energy beams may be staggered (e.g., in a direction).
  • the direction of may be along the direction of the gas flow, or at an angle relative to the direction of flow.
  • the angle may be perpendicular, or an angle different than perpendicular.
  • the plurality of energy beam may comprise 2, 3, 4, 5, 6, 7, 8, 9, or 10.
  • the plurality of energy beams may form an array. At least two of the plurality of energy beams may be controlled independently of each other. At least two of the plurality of energy beams may be controlled in concert. At least two of the plurality of energy beams may translate independently of each other. At least two of the plurality of energy beams may translate in concert. At least two of the plurality of energy beams may be controlled by the same controller. At least two of the plurality of energy beams may be controlled by different controllers.
  • the 3D printing system comprises a processor.
  • the processor may be a processing unit.
  • the controller may comprise a processing unit.
  • the processing unit may be central.
  • the processing unit may comprise a central processing unit (herein “CPU”).
  • the controllers or control mechanisms e.g., comprising a computer system
  • the processor e.g., 3D printer processor
  • the controller may control at least one component of the systems and/or apparatuses disclosed herein.
  • Fig. 4 is a schematic example of a computer system 400 that is programmed or otherwise configured to facilitate the formation of a 3D object according to the methods provided herein.
  • the computer system 400 can control (e.g., direct, monitor, and/or regulate) various features of printing methods, apparatuses and systems of the present disclosure, such as, for example, control force, translation, heating, cooling and/or maintaining the temperature of a powder bed, process parameters (e.g., chamber pressure), scanning rate (e.g., of the energy beam and/or the platform), scanning route of the energy source, position and/or temperature of the cooling member(s), application of the amount of energy emitted to a selected location, or any combination thereof.
  • the computer system 401 can be part of, or be in communication with, a 3D printing system or apparatus.
  • the computer may be coupled to one or more mechanisms disclosed herein, and/or any parts thereof.
  • the computer may be coupled to one or more sensors, valves, switches, motors, pumps, scanners, optical components, or any combination thereof.
  • the computer system 400 can include a processing unit 406 (also “processor,” “computer” and “computer processor” used herein).
  • the computer system may include memory or memory location 402 (e.g., random-access memory, read-only memory, flash memory), electronic storage unit 404 (e.g., hard disk), communication interface 403 (e.g., network adapter) for communicating with one or more other systems, and peripheral devices 405, such as cache, other memory, data storage and/or electronic display adapters.
  • the memory 402, storage unit 404, interface 403, and peripheral devices 405 are in communication with the processing unit 406 through a communication bus (solid lines), such as a motherboard.
  • the storage unit can be a data storage unit (or data repository) for storing data.
  • the computer system can be operatively coupled to a computer network (“network”) 401 with the aid of the communication interface.
  • the network can be the Internet, an internet and/or extranet, or an intranet and/or extranet that is in communication with the Internet.
  • the network is a telecommunication and/or data network.
  • the network can include one or more computer servers, which can enable distributed computing, such as cloud computing.
  • the network in some cases with the aid of the computer system, can implement a peer-to-peer network, which may enable devices coupled to the computer system to behave as a client or a server.
  • the processing unit can execute a sequence of machine-readable instructions, which can be embodied in a program or software.
  • the instructions may be stored in a memory location, such as the memory 602.
  • the instructions can be directed to the processing unit, which can subsequently program or otherwise configure the processing unit to implement methods of the present disclosure. Examples of operations performed by the processing unit can include fetch, decode, execute, and write back.
  • the processing unit may interpret and/or execute instructions.
  • the processor may include a microprocessor, a data processor, a central processing unit (CPU), a graphical processing unit (GPU), a system-on- chip (SOC), a co-processor, a network processor, an application specific integrated circuit (ASIC), an application specific instruction-set processor (ASIPs), a controller, a programmable logic device (PLD), a chipset, a field programmable gate array (FPGA), or any combination thereof.
  • the processing unit can be part of a circuit, such as an integrated circuit.
  • the storage unit 404 stores files, such as drivers, libraries and saved programs.
  • the storage unit can store user data (e.g., user preferences and user programs).
  • the computer system can include one or more additional data storage units that are external to the computer system, such as located on a remote server that is in communication with the computer system through an intranet or the Internet.
  • the 3D printer comprises communicating through a network.
  • the computer system can communicate with one or more remote computer systems through a network.
  • the computer system can communicate with a remote computer system of a user (e.g., operator).
  • remote computer systems include personal computers (e.g., portable PC), slate or tablet PC’s (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, Smart phones (e.g., Apple® iPhone, Android-enabled device, Blackberry®), or personal digital assistants.
  • a user e.g., client
  • Methods as described herein can be implemented by way of machine (e.g., computer processor) executable code stored on an electronic storage location of the computer system, such as, for example, on the memory 402 or electronic storage unit 404.
  • the machine executable or machine-readable code can be provided in the form of software.
  • the processor 406 can execute the code.
  • the code can be retrieved from the storage unit and stored on the memory for ready access by the processor.
  • the electronic storage unit can be precluded, and machine-executable instructions are stored on memory.
  • the code can be pre-compiled and configured for use with a machine have a processer adapted to execute the code, or can be compiled during runtime.
  • the code can be supplied in a programming language that can be selected to enable the code to execute in a pre-compiled or as-compiled fashion.
  • the processing unit includes one or more cores.
  • the computer system may comprise a single core processor, multi core processor, or a plurality of processors for parallel processing.
  • the processing unit may comprise one or more central processing unit (CPU) and/or a graphic processing unit (GPU).
  • the multiple cores may be disposed in a physical unit (e.g., Central Processing Unit, or Graphic Processing Unit).
  • the processing unit may include one or more processing units.
  • the physical unit may be a single physical unit.
  • the physical unit may be a die.
  • the physical unit may comprise cache coherency circuitry.
  • the multiple cores may be disposed in close proximity.
  • the physical unit may comprise an integrated circuit chip.
  • the integrated circuit chip may comprise one or more transistors.
  • the integrated circuit chip may comprise at least about 0.2 billion transistors (BT), 0.5 BT, 1 BT, 2 BT, 3 BT, 5 BT, 6 BT, 7 BT, 8 BT, 9 BT, 10 BT, 15 BT, 20 BT, 25 BT, 30 BT, 40 BT, or 50 BT.
  • the integrated circuit chip may comprise at most about 7 BT, 8 BT, 9 BT, 10 BT, 15 BT, 20 BT, 25 BT, 30 BT, 40 BT, 50 BT, 70 BT, or 100 BT.
  • the integrated circuit chip may comprise any number of transistors between the afore-mentioned numbers (e.g., from about 0.2 BT to about 100 BT, from about 1 BT to about 8 BT, from about 8 BT to about 40 BT, or from about 40 BT to about 100 BT).
  • the integrated circuit chip may have an area of at least about 50 mm 2 , 60 mm 2 , 70 mm 2 , 80 mm 2 , 90 mm 2 , 100 mm 2 , 200 mm 2 , 300 mm 2 , 400 mm 2 , 500 mm 2 , 600 mm 2 , 700 mm 2 , or 800 mm 2 .
  • the integrated circuit chip may have an area of at most about 50 mm 2 , 60 mm 2 , 70 mm 2 , 80 mm 2 , 90 mm 2 , 100 mm 2 , 200 mm 2 , 300 mm 2 , 400 mm 2 , 500 mm 2 , 600 mm 2 , 700 mm 2 , or 800 mm 2 .
  • the integrated circuit chip may have an area of any value between the afore-mentioned values (e.g., from about 50 mm 2 to about 800 mm 2 , from about 50 mm 2 to about 500 mm 2 , or from about 500 mm 2 to about 800 mm 2 ).
  • the close proximity may allow substantial preservation of communication signals that travel between the cores. The close proximity may diminish communication signal degradation.
  • a core as understood herein is a computing component having independent central processing capabilities.
  • the computing system may comprise a multiplicity of cores, which may be disposed on a single computing component.
  • the multiplicity of cores may include two or more independent central processing units.
  • the independent central processing units may constitute a unit that read and execute program instructions.
  • the independent central processing units may constitute parallel processing units.
  • the parallel processing units may be cores and/or digital signal processing slices (DSP slices).
  • DSP slices digital signal processing slices
  • the multiplicity of cores can be parallel cores.
  • the multiplicity of DSP slices can be parallel DSP slices.
  • the multiplicity of cores and/or DSP slices can function in parallel.
  • the multiplicity of cores may include at least about 2, 10, 40, 100, 400, 1000, 2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, 10000, 11000, 12000, 13000, 14000 or 15000 cores.
  • the multiplicity of cores may include at most about 1000, 2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, 10000, 11000, 12000, 13000, 14000, 15000, 20000, 30000, or 40000 cores.
  • the multiplicity of cores may include cores of any number between the aforementioned numbers (e.g., from about 2 to about 40000, from about 2 to about 400, from about 400 to about 4000, from about 2000 to about 4000, from about 4000 to about 10000, from about 4000 to about 15000, or from about 15000 to about 40000 cores).
  • the cores may be equivalent to multiple digital signal processor (DSP) slices (e.g., slices).
  • DSP digital signal processor
  • the plurality of DSP slices may be equal to any of plurality core values mentioned herein.
  • the processor may comprise low latency in data transfer (e.g., from one core to another).
  • Latency may refer to the time delay between the cause and the effect of a physical change in the processor (e.g., a signal). Latency may refer to the time elapsed from the source (e.g., first core) sending a packet to the destination (e.g., second core) receiving it (also referred as two-point latency). One-point latency may refer to the time elapsed from the source (e.g., first core) sending a packet (e.g., signal) to the destination (e.g., second core) receiving it, and the designation sending a packet back to the source (e.g., the packet making a round trip). The latency may be sufficiently low to allow a high number of floating point operations per second (FLOPS).
  • FLOPS floating point operations per second
  • the number of FLOPS may be at least about 0.1 Tera FLOPS (T-FLOPS), 0.2 T-FLOPS, 0.25 T-FLOPS, 0.5 T-FLOPS, 0.75 T-FLOPS, 1 T-FLOPS, 2 T-FLOPS, 3 T-FLOPS, 5 T-FLOPS, 6 T-FLOPS, 7 T-FLOPS, 8 T- FLOPS, 9 T-FLOPS, or 10 T-FLOPS.
  • T-FLOPS 0.1 Tera FLOPS
  • 0.2 T-FLOPS 0.25 T-FLOPS
  • 0.5 T-FLOPS 0.75 T-FLOPS
  • 1 T-FLOPS 1 T-FLOPS
  • 2 T-FLOPS 3 T-FLOPS
  • 5 T-FLOPS 6 T-FLOPS
  • 7 T-FLOPS 8 T- FLOPS
  • 9 T-FLOPS or 10 T-FLOPS.
  • the number of flops may be at most about 0.2 T- FLOPS, 0.25 T-FLOPS, 0.5 T-FLOPS, 0.75 T-FLOPS, 1 T-FLOPS, 2 T-FLOPS, 3 T-FLOPS, 5 T-FLOPS, 6 T-FLOPS, 7 T-FLOPS, 8 T-FLOPS, 9 T-FLOPS, 10 T-FLOPS, 20 T-FLOPS, 30 T-FLOPS, 50 T-FLOPS, 100 T- FLOPS, 1 P-FLOPS, 2 P-FLOPS, 3 P-FLOPS, 4 P- FLOPS, 5 P-FLOPS, 10 P-FLOPS, 50 P-FLOPS, 100 P-FLOPS, 1 EXA-FLOP, 2 EXA- FLOPS or 10 EXA-FLOPS.
  • the number of FLOPS may be any value between the aforementioned values (e.g., from about 0.1 T-FLOP to about 10 EXA-FLOPS, from about 0.1 T- FLOPS to about 1 T-FLOPS, from about 1 T-FLOPS to about 4 T-FLOPS, from about 4 T- FLOPS to about 10 T-FLOPS, from about 1 T-FLOPS to about 10 T-FLOPS, or from about 10 T-FLOPS to about 30 T-FLOPS, from about 50 T-FLOPS to about 1 EXA-FLOP, or from about 0.1 T-FLOP to about 10 EXA-FLOPS).
  • the operations per second may be measured as (e.g., Giga) multiply-accumulate operations per second (e.g., MACs or GMACs).
  • the MACs value can be equal to any of the T-FLOPS values mentioned herein measured as Tera-MACs (T-MACs) instead of T-FLOPS respectively.
  • the FLOPS can be measured according to a benchmark.
  • the benchmark may be a HPC Challenge Benchmark.
  • the benchmark may comprise mathematical operations (e.g., equation calculation such as linear equations), graphical operations (e.g., rendering), or encryption/decryption benchmark.
  • the benchmark may comprise a High Performance LINPACK, matrix multiplication (e.g., DGEMM), sustained memory bandwidth to/from memory (e.g., STREAM), array transposing rate measurement (e.g., PTRANS), Random- access, rate of Fast Fourier Transform (e.g., on a large one-dimensional vector using the generalized Cooley-Tukey algorithm), or Communication Bandwidth and Latency (e.g., MPI- centric performance measurements based on the effective bandwidth/latency benchmark).
  • LINPACK may refer to a software library for performing numerical linear algebra on a digital computer.
  • DGEMM may refer to double precision general matrix multiplication.
  • STREAM benchmark may refer to a synthetic benchmark designed to measure sustainable memory bandwidth (in MB/s) and a corresponding computation rate for four simple vector kernels (Copy, Scale, Add and Triad).
  • PTRANS benchmark may refer to a rate measurement at which the system can transpose a large array (global).
  • MPI refers to Message Passing Interface.
  • the computer system includes hyper-threading technology.
  • the computer system may include a chip processor with integrated transform, lighting, triangle setup, triangle clipping, rendering engine, or any combination thereof.
  • the rendering engine may be capable of processing at least about 10 million polygons per second.
  • the rendering engines may be capable of processing at least about 10 million calculations per second.
  • the GPU may include a GPU by Nvidia, ATI Technologies, S3 Graphics, Advanced Micro Devices (AMD), or Matrox.
  • the processing unit may be able to process algorithms comprising a matrix or a vector.
  • the core may comprise a complex instruction set computing core (CISC), or reduced instruction set computing (RISC).
  • the computer system includes an electronic chip that is reprogrammable (e.g., field programmable gate array (FPGA)).
  • FPGA field programmable gate array
  • the FPGA may comprise Tabula, Altera, or Xilinx FPGA.
  • the electronic chips may comprise one or more programmable logic blocks (e.g., an array).
  • the logic blocks may compute combinational functions, logic gates, or any combination thereof.
  • the computer system may include custom hardware.
  • the custom hardware may comprise an algorithm.
  • the computer system includes configurable computing, partially reconfigurable computing, reconfigurable computing, or any combination thereof.
  • the computer system may include a FPGA.
  • the computer system may include an integrated circuit that performs the algorithm.
  • the reconfigurable computing system may comprise FPGA, CPU, GPU, or multi-core microprocessors.
  • the reconfigurable computing system may comprise a High-Performance Reconfigurable Computing architecture (HPRC).
  • HPRC High-Performance Reconfigurable Computing architecture
  • the partially reconfigurable computing may include module-based partial reconfiguration, or difference-based partial reconfiguration.
  • the FPGA may comprise configurable FPGA logic, and/or fixed-function hardware comprising multipliers, memories, microprocessor cores, first in-first out (FIFO) and/or error correcting code (ECC) logic, digital signal processing (DSP) blocks, peripheral Component interconnect express (PCI Express) controllers, ethernet media access control (MAC) blocks, or high-speed serial transceivers.
  • DSP blocks can be DSP slices.
  • the computing system includes an integrated circuit.
  • the computing system may include an integrated circuit that performs the algorithm (e.g., control algorithm).
  • the physical unit e.g., the cache coherency circuitry within
  • the clock time may be at least about 0.1 Gigabits per second (Gbit/s), 0.5 Gbit/s, 1 Gbit/s, 2 Gbit/s, 5 Gbit/s, 6 Gbit/s, 7 Gbit/s, 8 Gbit/s, 9 Gbit/s, 10 Gbit/s, or 50 Gbit/s.
  • the physical unit may have a clock time of any value between the afore-mentioned values (e.g., from about 0.1 Gbit/s to about 50 Gbit/s, or from about 5 Gbit/s to about 10 Gbit/s).
  • the physical unit may produce the algorithm output in at most about 0.1 microsecond (ps), 1 ps, 10ps, 100ps, or 1 millisecond (ms).
  • the physical unit may produce the algorithm output in any time between the above mentioned times (e.g., from about 0.1 ps, to about 1 ms, from about 0.1 ps, to about 100 ps, or from about 0.1 me to about 1 Ops).
  • the controller uses calculations, real time measurements, or any combination thereof to regulate the energy beam(s).
  • the sensor e.g., temperature and/or positional sensor
  • the sensor may provide a signal (e.g., input for the controller and/or processor) at a rate of at least about 0.1 KHz, 1 KHz, 10KHz, 10OKHz, 10OOKHz, or 10OOOKHz).
  • the sensor may provide a signal at a rate between any of the above-mentioned rates (e.g., from about 0.1 KHz to about lOOOOKHz, from about 0.1 KHz to about lOOOKHz, or from about 1000 KHz to about lOOOOKHz).
  • the memory bandwidth of the processing unit may be at least about 1 gigabytes per second (Gbytes/s), 10 Gbytes/s, 100 Gbytes/s, 200 Gbytes/s, 300 Gbytes/s, 400 Gbytes/s, 500 Gbytes/s, 600 Gbytes/s, 700 Gbytes/s, 800 Gbytes/s, 900 Gbytes/s, or 1000 Gbytes/s.
  • Gbytes/s gigabytes per second
  • the memory bandwidth of the processing unit may be at most about 1 gigabyte per second (Gbytes/s), 10 Gbytes/s, 100 Gbytes/s, 200 Gbytes/s, 300 Gbytes/s, 400 Gbytes/s, 500 Gbytes/s, 600 Gbytes/s, 700 Gbytes/s, 800 Gbytes/s, 900 Gbytes/s, or 1000 Gbytes/s.
  • Gbytes/s gigabyte per second
  • the memory bandwidth of the processing unit may have any value between the afore-mentioned values (e.g., from about 1 Gbytes/s to about 1000 Gbytes/s, from about 100 Gbytes/s to about 500 Gbytes/s, from about 500 Gbytes/s to about 1000 Gbytes/s, or from about 200 Gbytes/s to about 400 Gbytes/s).
  • the sensor measurements may be realtime measurements.
  • the real time measurements may be conducted during the 3D printing process.
  • the real-time measurements may be in situ measurements in the 3D printing system and/or apparatus.
  • the real time measurements may be during the formation of the 3D object.
  • the processing unit may use the signal obtained from the at least one sensor to provide a processing unit output, which output is provided by the processing system at a speed of at most about 10Omin, 50min, 25min, 15min, 10min, 5min, 1 min, 0.5min (e.g., 30sec), 15sec, 10sec, 5sec, 1sec, 0.5sec, 0.25sec, 0.2sec, 0.1sec, 80 milliseconds (msec), 50msec, 10msec, 5msec, 1 msec, 80 microseconds (psec), 50 psec, 20psec, 10 psec, 5 psec, or 1 psec.
  • the processing unit may use the signal obtained from the at least one sensor to provide a processing unit output, which output is provided at a speed of any value between the afore-mentioned values (e.g., from about 100 min to about 1 psec, from about 100 min to about 10 min, from about 10 min to about 1 min, from about 5min to about 0.5 min, from about 30 sec to about 0.1 sec, from about 0.1 sec to about 1 msec, from about 80 msec to about 10 psec, from about 50 psec to about 1 psec, from about 20 psec to about 1 psec, or from about 10 psec to about 1 psec).
  • the processing unit comprises an output.
  • the processing unit output may comprise an evaluation of the temperature at a location, position at a location (e.g., vertical and/or horizontal), or a map of locations.
  • the location may be on the target surface.
  • the map may comprise a topological or temperature map.
  • the temperature sensor may comprise a temperature imaging device (e.g., IR imaging device).
  • the processing unit receives a signal from a sensor.
  • the processing unit may use the signal obtained from the at least one sensor in an algorithm that is used in controlling the energy beam.
  • the algorithm may comprise the path of the energy beam. In some instances, the algorithm may be used to alter the path of the energy beam on the target surface. The path may deviate from a cross section of a model corresponding to the desired 3D object.
  • the processing unit may use the output in an algorithm that is used in determining the manner in which a model of the desired 3D object may be sliced.
  • the processing unit may use the signal obtained from the at least one sensor in an algorithm that is used to configure one or more parameters and/or apparatuses relating to the 3D printing process.
  • the parameters may comprise a characteristic of the energy beam.
  • the parameters may comprise movement of the platform and/or material bed.
  • the parameters may comprise relative movement of the energy beam and the material bed. In some instances, the energy beam, the platform (e.g., material bed disposed on the platform), or both may translate.
  • the controller may use historical data for the control.
  • the processing unit may use historical data in its one or more algorithms.
  • the parameters may comprise the height of the layer of powder material disposed in the enclosure and/or the gap by which the cooling element (e.g., heat sink) is separated from the target surface.
  • the target surface may be the exposed layer of the material bed.
  • aspects of the systems, apparatuses, and/or methods provided herein, such as the computer system can be embodied in programming (e.g., using a software).
  • Various aspects of the technology may be thought of as “product,” “object,” or “articles of manufacture” typically in the form of machine (or processor) executable code and/or associated data that is carried on or embodied in a type of machine-readable medium.
  • Machine-executable code can be stored on an electronic storage unit, such memory (e.g., read-only memory, random-access memory, flash memory) or a hard disk.
  • the storage may comprise non-volatile storage media.
  • “Storage” type media can include any or all of the tangible memory of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives, external drives, and the like, which may provide non-transitory storage at any time for the software programming.
  • the computer system comprises a memory.
  • the memory may comprise a random-access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), synchronous dynamic random access memory (SDRAM), ferroelectric random access memory (FRAM), read only memory (ROM), programmable read only memory (PROM), erasable programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), a flash memory, or any combination thereof.
  • RAM random-access memory
  • DRAM dynamic random access memory
  • SRAM static random access memory
  • SDRAM synchronous dynamic random access memory
  • FRAM ferroelectric random access memory
  • ROM read only memory
  • PROM programmable read only memory
  • EPROM erasable programm
  • the flash memory may comprise a negative-AND (NAND) or NOR logic gates.
  • a NAND gate (negative-AND) may be a logic gate which produces an output which is false only if all its inputs are true.
  • the output of the NAND gate may be complement to that of the AND gate.
  • the storage may include a hard disk (e.g., a magnetic disk, an optical disk, a magneto-optic disk, a solid-state disk, etc.), a compact disc (CD), a digital versatile disc (DVD), a floppy disk, a cartridge, a magnetic tape, and/or another type of computer-readable medium, along with a corresponding drive.
  • All or portions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another, for example, from a management server or host computer into the computer platform of an application server.
  • another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links.
  • the physical elements that carry such waves, such as wired or wireless links, optical links, or the like, also may be considered as media bearing the software.
  • Non-volatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like, such as may be used to implement the databases.
  • Volatile storage media can include dynamic memory, such as main memory of such a computer platform.
  • Tangible transmission media can include coaxial cables, wire (e.g., copper wire), and/or fiber optics, including the wires that comprise a bus within a computer system.
  • Carrier-wave transmission media may take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications.
  • RF radio frequency
  • IR infrared
  • Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage medium with patterns of holes, a RAM, a ROM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, any other medium from which a computer may read programming code and/or data, or any combination thereof.
  • the memory and/or storage may comprise a storing device external to and/or removable from device, such as a Universal Serial Bus (USB) memory stick, or/and a hard disk.
  • USB Universal Serial Bus
  • the computer system comprises an electronic display.
  • the computer system can include or be in communication with an electronic display that comprises a user interface (Ul) for providing, for example, a model design or graphical representation of a 3D object to be printed.
  • Ul graphical user interface
  • the computer system can monitor and/or control various aspects of the 3D printing system.
  • the control may be manual and/or programmed.
  • the control may rely on feedback mechanisms (e.g., from the one or more sensors).
  • the control may rely on historical data.
  • the feedback mechanism may be pre-programmed.
  • the feedback mechanisms may rely on input from sensors (described herein) that are connected to the control unit (e.g., control system or control mechanism e.g., computer) and/or processing unit.
  • the computer system may store historical data concerning various aspects of the operation of the 3D printing system.
  • the historical data may be retrieved at predetermined times and/or at a whim.
  • the historical data may be accessed by an operator and/or by a user.
  • the historical, sensor, and/or operative data may be provided in an output unit such as a display unit.
  • the output unit (e.g., monitor) may output various parameters of the 3D printing system (as described herein) in real time or in a delayed time.
  • the output unit may output the current 3D printed object, the ordered 3D printed object, or both.
  • the output unit may output the printing progress of the 3D printed object.
  • the output unit may output at least one of the total time, time remaining, and time expanded on printing the 3D object.
  • the output unit may output (e.g., display, voice, and/or print) the status of sensors, their reading, and/or time for their calibration or maintenance.
  • the output unit may output the type of material(s) used and various characteristics of the material(s) such as temperature and flowability of the pre-transformed material.
  • the output unit may output the amount of oxygen, water, and pressure in the printing chamber (e.g., the chamber where the 3D object is being printed).
  • the computer may generate a report comprising various parameters of the 3D printing system, method, and or objects at predetermined time(s), on a request (e.g., from an operator), and/or at a whim.
  • the output unit may comprise a screen, printer, or speaker.
  • the control system may provide a report.
  • the report may comprise any items recited as optionally output by the output unit.
  • the system and/or apparatus described herein e.g., controller
  • the input device may comprise a keyboard, touch pad, or microphone.
  • the output device may be a sensory output device.
  • the output device may include a visual, tactile, or audio device.
  • the audio device may include a loudspeaker.
  • the visual output device may include a screen and/or a printed hard copy (e.g., paper).
  • the output device may include a printer.
  • the input device may include a camera, a microphone, a keyboard, or a touch screen.
  • the computer system includes a user interface.
  • the computer system can include, or be in communication with, an electronic display unit that comprises a user interface (Ul) for providing, for example, a model design or graphical representation of an object to be printed.
  • Ul user interface
  • Examples of Ul’s include a graphical user interface (GUI) and web- based user interface.
  • the historical and/or operative data may be displayed on a display unit.
  • the computer system may store historical data concerning various aspects of the operation of the cleaning system.
  • the historical data may be retrieved at predetermined times and/or at a whim.
  • the historical data may be accessed by an operator and/or by a user.
  • the display unit may display various parameters of the printing system (as described herein) in real time or in a delayed time.
  • the display unit may display the desired printed 3D object (e.g., according to a model), the printed 3D object, real time display of the 3D object as it is being printed, or any combination thereof.
  • the display unit may display the cleaning progress of the object, or various aspects thereof.
  • the display unit may display at least one of the total time, time remaining, and time expanded on the cleaned object during the cleaning process.
  • the display unit may display the status of sensors, their reading, and/or time for their calibration or maintenance.
  • the display unit may display the type or types of material used and various characteristics of the material or materials such as temperature and flowability of the pre-transformed material.
  • the display unit may display the amount of a certain gas in the chamber.
  • the gas may comprise an oxidizing gas (e.g., oxygen), hydrogen, water vapor, or any of the gasses mentioned herein.
  • the gas may comprise a reactive agent.
  • the display unit may display the pressure in the chamber.
  • the computer may generate a report comprising various parameters of the methods, objects, apparatuses, or systems described herein. The report may be generated at predetermined time(s), on a request (e.g., from an operator) or at a whim.
  • Methods, apparatuses, and/or systems of the present disclosure can be implemented by way of one or more algorithms.
  • An algorithm can be implemented by way of software upon execution by one or more computer processors.
  • the processor can be programmed to calculate the path of the energy beam and/or the power per unit area emitted by the energy source (e.g., that should be provided to the material bed in order to achieve the desired result).
  • Other control and/or algorithm examples may be found in provisional patent application number 62/325,402, which is incorporated herein by reference in its entirety.
  • the 3D printer comprises and/or communicates with a multiplicity of processors.
  • the processors may form a network architecture.
  • the 3D printer may comprise at least one processor (referred herein as the “3D printer processor”).
  • the 3D printer may comprise a plurality of processors. At least two of the plurality of the 3D printer processors may interact with each other. At times, at least two of the plurality of the 3D printer processors may not interact with each other.
  • a 3D printer processor interacts with at least one processor that acts as a 3D printer interface (also referred to herein as “machine interface processor”).
  • the processor e.g., machine interface processor
  • the processor may be stationary or mobile.
  • the processor may be a remote computer systems.
  • the machine interface one or more processors may be connected to at least one 3D printer processor.
  • the connection may be through a wire (e.g., cable) or be wireless (e.g., via Bluetooth technology).
  • the machine interface may be hardwired to the 3D printer.
  • the machine interface may directly connect to the 3D printer (e.g., to the 3D printer processor).
  • the machine interface may indirectly connect to the 3D printer (e.g., through a server, or through wireless communication).
  • the cable may comprise coaxial cable, shielded twisted cable pair, unshielded twisted cable pair, structured cable (e.g., used in structured cabling), or fiber-optic cable.
  • the machine interface processor directs 3D print job production, 3D printer management, 3D printer monitoring, or any combination thereof.
  • the machine interface processor may not be able to influence (e.g., direct, or be involved in) preprint or 3D printing process development.
  • the machine management may comprise controlling the 3D printer controller (e.g., directly or indirectly).
  • the printer controller may direct start (e.g., initiation) of a 3D printing process, stopping a 3D printing process, maintenance of the 3D printer, clearing alarms (e.g., concerning safety features of the 3D printer).
  • the machine interface processor allows monitoring of the 3D printing process (e.g., accessible remotely or locally).
  • the machine interface processor may allow viewing a log of the 3D printing and status of the 3D printer at a certain time (e.g., 3D printer snapshot).
  • the machine interface processor may allow to monitor one or more 3D printing parameters.
  • the one or more printing parameters monitored by the machine interface processor can comprise 3D printer status (e.g., 3D printer is idle, preparing to 3D print, 3D printing, maintenance, fault, or offline), active 3D printing (e.g., including a build module number), status and/or position of build module(s), status of build module and processing chamber engagement, type and status of pre-transformed material used in the 3D printing (e.g., amount of pre-transformed material remaining in the reservoir), status of a filter, atmosphere status (e.g., pressure, gas level(s)), ventilator status, layer dispensing mechanism status (e.g., position, speed, rate of deposition, level of exposed layer of the material bed), status of the optical system (e.g., optical window, mirror), status of scanner, alarm (, boot log, status change, safety events, motion control commands (e.g., of the energy beam, or of the layer dispensing mechanism), or printed 3D object status (e.g., what layer number is being printed),
  • 3D printer status
  • the machine interface processor allows monitoring the 3D print job management.
  • the 3D print job management may comprise status of each build module (e.g., atmosphere condition, position in the enclosure, position in a queue to go in the enclosure, position in a queue to engage with the processing chamber, position in queue for further processing, power levels of the energy beam, type of pre-transformed material loaded, 3D printing operation diagnostics, status of a filter.
  • the machine interface processor e.g., output device thereof
  • the machine interface processor may allow viewing and/or editing any of the job management and/or one or more printing parameters.
  • the machine interface processor may show the permission level given to the user (e.g., view, or edit).
  • the machine interface processor may allow viewing and/or assigning a certain 3D object to a particular build module, prioritize 3D objects to be printed, pause 3D objects during 3D printing, delete 3D objects to be printed, select a certain 3D printer for a particular 3D printing job, insert and/or edit considerations for restarting a 3D printing job that was removed from 3D printer.
  • the machine interface processor may allow initiating, pausing, and/or stopping a 3D printing job.
  • the machine interface processor may output message notification (e.g., alarm), log (e.g., other than Excursion log or other default log), or any combination thereof.
  • the 3D printer interacts with at least one server (e.g., print server).
  • the 3D print server may be separate or interrelated in the 3D printer.
  • One or more users may interact with the one or more 3D printing processors through one or more user processors (e.g., respectively). The interaction may be in parallel and/or sequentially.
  • the users may be clients.
  • the users may belong to entities that desire a 3D object to be printed, or entities who prepare the 3D object printing instructions.
  • the one or more users may interact with the 3D printer (e.g., through the one or more processors of the 3D printer) directly and/or indirectly. Indirect interaction may be through the server.
  • One or more users may be able to monitor one or more aspects of the 3D printing process.
  • One or more users can monitor aspects of the 3D printing process through at least one connection (e.g., network connection).
  • connection e.g., network connection
  • Direct connection may be using a local area network (LAN), and/or a wide area network (WAN).
  • the network may interconnect computers within a limited area (e.g., a building, campus, neighborhood).
  • the limited area network may comprise Ethernet or Wi-Fi.
  • the network may have its network equipment and interconnects locally managed.
  • the network may cover a larger geographic distance than the limited area.
  • the network may use telecommunication circuits and/or internet links.
  • the network may comprise Internet Area Network (IAN), and/or the public switched telephone network (PSTN).
  • the communication may comprise web communication.
  • the aspect of the 3D printing process may comprise a 3D printing parameter, machine status, or sensor status.
  • the 3D printing parameter may comprise hatch strategy, energy beam power, energy beam speed, energy beam focus, thickness of a layer (e.g., of hardened material or of pretransformed material).
  • a user develops at least one 3D printing instruction and directs the 3D printer (e.g., through communication with the 3D printer processor) to print in a desired manner according to the developed at least one 3D printing instruction.
  • a user may or may not be able to control (e.g., locally or remotely) the 3D printer controller.
  • a client may not be able to control the 3D printing controller (e.g., maintenance of the 3D printer).
  • the user may use realtime and/or historical 3D printing data.
  • the 3D printing data may comprise metrology data, or temperature data.
  • the user processor may comprise quality control.
  • the quality control may use a statistical method (e.g., statistical process control (SPC)).
  • SPC statistical process control
  • the user processor may log excursion log, report when a signal deviates from the nominal level, or any combination thereof.
  • the user processor may generate a configurable response.
  • the configurable response may comprise a print/pause/stop command (e.g., automatically) to the 3D printer (e.g., to the 3D printing processor).
  • the configurable response may be based on a user defined parameter, threshold, or any combination thereof.
  • the configurable response may result in a user defined action.
  • the user processor may control the 3D printing process and ensure that it operates at its full potential. For example, at its full potential, the 3D printing process may make a maximum number of 3D object with a minimum of waste and/or 3D printer down time.
  • the SPC may comprise a control chart, design of experiments, and/or focus on continuous improvement.
  • the fundamental length scale (e.g., the diameter, spherical equivalent diameter, diameter of a bounding circle, or largest of height, width, depth, and length; abbreviated herein as “FLS”) of the printed 3D object or a portion thereof can be at least about 50 micrometers (pm), 80pm, 100pm, 120pm, 150pm, 170pm, 200pm, 230pm, 250pm, 270pm, 300pm, 400pm, 500pm, 600pm, 700pm, 800pm, 1 mm, 1.5mm, 2mm, 3mm, 5mm, 1cm, 1.5cm, 2cm, 10cm, 20cm, 30cm, 40cm, 50cm, 60cm, 70cm, 80cm, 90cm, 1 m, 2m, 3m, 4m, 5m, 10m, 50m, 80m, or 100m.
  • the FLS of the printed 3D object or a portion thereof can be at most about 150pm, 170pm, 200pm, 230pm, 250pm, 270pm, 300pm, 400pm, 500pm, 600pm, 700pm, 800pm, 1 mm, 1.5mm, 2mm, 3mm, 5mm, 1cm, 1.5cm, 2cm, 10cm, 20cm, 30cm, 40cm, 50cm, 60cm, 70cm, 80cm, 90cm, 1 m, 2m, 3m, 4m, 5m, 10m,
  • the FLS of the printed 3D object or a portion thereof can any value between the afore-mentioned values (e.g., from about 50 pm to about 1000m, from about 500 pm to about 100m, from about 50 pm to about 50cm, or from about 50cm to about 1000m). In some cases, the FLS of the printed 3D object or a portion thereof may be in between any of the afore-mentioned FLS values.
  • the portion of the 3D object may be a heated portion or disposed portion (e.g., tile).
  • the layer of pre-transformed material (e.g., powder) is of a predetermined height (thickness).
  • the layer of pre-transformed material can comprise the material prior to its transformation in the 3D printing process.
  • the layer of pre-transformed material may have an upper surface that is substantially flat, leveled, or smooth. In some instances, the layer of pre-transformed material may have an upper surface that is not flat, leveled, or smooth.
  • the layer of pre-transformed material may have an upper surface that is corrugated or uneven.
  • the layer of pre-transformed material may have an average or mean (e.g., pre-determined) height.
  • the height of the layer of pre-transformed material may be at least about 5 micrometers (pm), 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 200 pm, 300 pm, 400 pm, 500 pm, 600 pm, 700 pm,
  • the height of the layer of pre-transformed material may be at most about 5 micrometers (pm), 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 200 pm, 300 pm, 400 pm, 500 pm, 600 pm, 700 pm, 800 pm, 900 pm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 200 mm, 300 mm, 400 mm, 500 mm, 600 mm, 700 mm, 800 mm, 900 mm, or 1000 mm.
  • pm micrometers
  • the height of the layer of pre-transformed material may be any number between the afore-mentioned heights (e.g., from about 5pm to about 1000mm, from about 5pm to about 1 mm, from about 25pm to about 1 mm, or from about 1 mm to about 1000mm).
  • the “height” of the layer of material e.g., powder
  • the layer of hardened material may be a sheet of metal.
  • the layer of hardened material may be fabricated using a 3D manufacturing methodology. Occasionally, the first layer of hardened material may be thicker than a subsequent layer of hardened material.
  • the first layer of hardened material may be at least about 1.1 times, 1 .2 times, 1 .4 times, 1.6 times, 1.8 times, 2 times, 4 times, 6 times, 8 times, 10 times, 20 times, 30 times, 50 times, 100 times, 500 times, 1000 times, or thicker (higher) than the average (or mean) thickness of a subsequent layer of hardened material, the average thickens of an average subsequent layer of hardened material, or the average thickness of any of the subsequent layers of hardened material.
  • the very first layer of hardened material formed in the material bed by 3D printing may be referred herein as the “bottom skin” layer.
  • one or more intervening layers separate adjacent components from one another.
  • the one or more intervening layers can have a thickness of at most about 10 micrometers (“microns”), 1 micron, 500 nanometers (“nm”), 100 nm, 50 nm, 10 nm, or 1 nm.
  • the one or more intervening layers can have a thickness of at least about 10 micrometers (“microns”), 1 micron, 500 nanometers (“nm”), 100 nm, 50 nm,
  • a first layer is adjacent to a second layer when the first layer is in direct contact with the second layer.
  • a first layer is adjacent to a second layer when the first layer is separated from the second layer by a third layer.
  • adjacent to may be ‘above’ or ‘below.’ Below can be in the direction of the gravitational force or towards the platform. Above can be in the direction opposite to the gravitational force or away from the platform.
  • a projected energy beam heats a portion of the material bed. The projected energy beam may irradiate a portion of the material bed.
  • the heat or irradiation of the portion of the material bed may generate debris (e.g., metal vapor, molten metal, plasma, etc.).
  • the debris may be disposed in the enclosure (e.g., processing chamber).
  • the debris may be disposed in the atmosphere of the enclosure).
  • the debris may be disposed on one or more components within the enclosure.
  • the debris may be disposed on one or more internal surfaces (e.g., walls or optical window) of the enclosure.
  • the debris may float within the enclosure atmosphere.
  • the debris e.g., accumulation thereof
  • the enclosure may comprise a gas flow (e.g., mechanism) that allows displacement (e.g., removal) of the debris from a position in the enclosure atmosphere (e.g., from the entire enclosure atmosphere).
  • the gas flow mechanism (also referred to herein as “gas flow director,” “gas flow manager,” “gas flow management system,” or “gas flow management arrangement”) comprises structures that at least partially dictate the flowing of gas across the (e.g., entire) enclosure and/or a portion of the enclosure.
  • the gas flow mechanism can be used to at least partially control a characteristic of gas flow adjacent (e.g., over) the target surface and/or the platform.
  • Over the target surface may comprise at most 2cm, 5cm, 10cm, or 20cm above the target surface (e.g., the exposed surface of the material bed).
  • Target surface may refer to a surface that is a radiation target for the energy beam.
  • the gas flow mechanism can include a gas inlet portion that at least partially controls the flow of gas entering into the enclosure.
  • the gas flow mechanism can include a gas outlet portion that at least partially controls the flow of gas exiting the enclosure.
  • the gas flow mechanism can be used to at least partially control a characteristic of gas flow adjacent to or within a recessed portion of the enclosure (e.g., to purge the recessed portion).
  • the gas flow director can include the gas inlet portion, the gas outlet portion, features for purging a recessed portion of the enclosure, or any suitable combination thereof.
  • the recessed portion may be at the ceiling of the enclosure.
  • the recessed portion may be disposed at a wall of the enclosure opposing to the target surface.
  • the gas may comprise an inert gas (e.g., nitrogen and/or argon).
  • the gas may flow in bulk.
  • the gas may flow in one or more streams.
  • the gas may comprise a non-reacting (e.g., inert) gas.
  • the gas may comprise an reactive agent depleted gas and/or water depleted gas.
  • the flow of the gas may comprise flowing across at least a portion of the height (e.g., Y axis. See Fig. 8) of the enclosure.
  • the flow of the gas may comprise flowing across the entire height of the enclosure.
  • the flow of the gas may comprise flowing across at least a portion of the depth (e.g., Z axis. See Fig. 8) of the enclosure.
  • the flow of the gas may comprise flowing across the entire depth of the enclosure.
  • the flow of the gas may comprise flowing across at least a portion of the width (e.g., X axis. See Fig. 8) of the enclosure (e.g., also referred herein as the length of the enclosure).
  • the flow of the gas may comprise flowing across the entire width of the enclosure.
  • the flow of gas may comprise flowing onto an internal surface of the optical window (e.g., facing the exposed surface of the material bed, e.g., Fig. 15, 1543).
  • the area adjacent to the optical window may comprise one or more slots (e.g., a slot per optical window, or a single slot for all optical windows, or dispersed multiple slots across one or more optical windows), one or more channels, or a combination thereof.
  • the flow of gas may comprise flowing through the one or more slots, channels, or a combination thereof, on to the internal surface of the optical window.
  • the slot and/or channel may facilitate directing the flow of gas onto the internal surface of the optical window (e.g., 1543).
  • the gas flow may be optionally evacuated from an area adjacent (e.g., directly adjacent) to the one or more optical windows (e.g., from the 1541 side to the 1542 side of the optical window 1515).
  • the flow of gas may reduce the amount of (e.g., prevent) powder, soot, and/or debris from adhering to the internal surface (e.g., 1543) of the one or more optical windows.
  • the flow of gas may reduce the amount of (e.g., prevent) powder, soot, and/or debris from obstructing an optical path of the energy beam (e.g., 1501) that travels from the optical window to the exposed surface of the material bed (e.g., 1504).
  • Components of Fig. 15 can be disposed relative to gravitational vector 1599 pointing to gravitational center G.
  • the flow of gas may be (e.g., substantially) lateral.
  • the flow of gas may be (e.g., substantially) horizontal.
  • the gas may flow along and/or towards the one or more optical windows.
  • the gas may flow in a plurality of gas streams (e.g., Fig. 16, 1635).
  • the gas streams may be spread across at least a portion of the (e.g., entire) height and/or depth of the enclosure.
  • the gas streams may be evenly spread.
  • the gas streams may not be evenly spread (e.g., across at least a portion of the enclosure height and/or depth).
  • the gas streams may flow across at least a portion of the enclosure height and/or depth Across the enclosure, the gas streams may flow in the same direction.
  • the same direction may comprise from the gas-inlet to the gas-outlet.
  • the same direction may comprise from one edge of the enclosure to the opposite end).
  • the same direction may comprise from the gas-inlet to the gas-outlet.
  • the gas flow may flow laterally across at least a portion of the (e.g., height and/or depth of the) enclosure.
  • the gas flow may flow laminarly across at least a portion of the (e.g., height and/or depth of the) enclosure.
  • the at least a portion of the enclosure may comprise the processing cone (e.g., Fig. 15, 1530).
  • the gas streams may not flow in the same direction.
  • one or more gas streams may flow in the same direction and one or more gas streams may flow in the opposite direction.
  • Fig. 16 shows an example simulation of gas streams at different velocities across the width and height area of the gas flow mechanism. Components of Fig. 16 can be disposed relative to gravitational vector 1699 pointing to gravitational center G.
  • the gas flow (e.g., in the at least one stream) may comprise a laminar flow.
  • the gas flow may comprise flow in a constant velocity during at least a portion of the 3D printing.
  • the gas flow may comprise flow in a constant velocity during the operation of the energy beam (e.g., during the transformation of at least a portion of the material bed).
  • Laminar flow may comprise fluid flow (e.g., gas flow) in (e.g., substantially) parallel layers.
  • the gas flow may comprise flow in a varied velocity during at least a portion of the 3D printing.
  • the gas flow may comprise flow in a varied velocity during the operation of the energy beam (e.g., during the transformation of at least a portion of the material bed).
  • the gas streams may comprise a turbulent flow.
  • Turbulent flow may comprise (e.g., random, and/or irregular) fluctuations in pressure, magnitude, direction and/or flow velocity of the gas.
  • Turbulent flow may comprise a chaotic flow.
  • the chaotic flow comprises circular, swirling, agitated, rough, irregular, disordered, disorganized, cyclonic, spiraling, vortex, or agitated movement of the gas.
  • the mixing comprises laminar, vertical, horizontal, or angular movement.
  • the gas flow within at least two of the gas streams within the enclosure may be of a different velocity and/or density.
  • the gas flow within at least two of the gas streams within the enclosure may be of the same magnitude.
  • the gas flow within at least two of the gas streams within the enclosure may be of variable magnitude.
  • the gas flow (e.g., of at least one gas stream) within the enclosure may be free of standing vortices.
  • a standing vortex may be described as a vortex in which the axis of fluid rotation remains in (e.g., substantially) the same location, e.g., not transmitted with the rest of the flow.
  • Turbulent flow of gas within the enclosure may generate a vortex that transmits with the rest of the flow, thus generating a gas flow without standing vortices.
  • the gas flow mechanism may not comprise (i) recirculation of gas, (ii) gas flow stagnation, or (iii) static vortices, within the enclosure.
  • the gas flow mechanism may not comprise recirculation of gas within the enclosure.
  • the gas flow (e.g., in the enclosure) may be continuous. Continuously may be during the operation of the 3D printer (e.g., before, during and/or after the 3D printing or a portion thereof).
  • the gas stream(s) may be altered (e.g., reduced, or cease to flow) when the energy beam is not operating (e.g., to transform at least a portion of the material bed).
  • at least portion of the gas flow may be changed before, during or after dispensing mechanism performs dispensing.
  • the alteration may be in velocity, gas stream trajectory, gas content, pressure, humidity content, oxidizing gas content, gas flow cross section (e.g., at full width half maximum) or any combination thereof.
  • the velocity of the gas (e.g., in the enclosure) can be at least about 0.1 m/s, 0.2 m/s, 0.3 m/s, 0.5 m/s, 0.7 m/s, 0.8 m/s, 1 m/s,
  • the velocity of gas can be at most about 0.1 m/s, 0.2 m/s, 0.3 m/s, 0.5 m/s, 0.7 m/s, 0.8 m/s, 1 m/s, 2 m/s, 5 m/s, 10 m/s, 15 m/s, 20 m/s, 30 m/s or 50 m/s.
  • the velocity of the gas (e.g., in the enclosure) can be between any of the afore-mentioned values (e.g., from about 0.1 m/s to about 50 m/s, from about 0.1 m/s to about 1 m/s, from about 2 m/s to about 20 m/s, from about 30 m/s to about 50 m/s, or from about 0.7 m/s to about 1 m/s).
  • the velocity of the gas can be during at least a portion of the 3D printing.
  • the velocity of the gas can refer to its flow velocity along any one of its components.
  • the velocity of the gas can have a component along the width of the chamber (X direction, Fig. 8).
  • the velocity of the gas can have a component along the height of the chamber (Y direction, Fig. 8).
  • the velocity of the gas can have a component along the depth of the chamber (Z direction, Fig. 8).
  • a layer dispensing mechanism is reversibly parked in an isolatable ancillary chamber when it does not perform a layer dispensing operation.
  • the energy beam may be projected on the material bed when the layer dispensing mechanism resides within the ancillary chamber (e.g., isolated from the processing chamber), and the gas flow may continue during operation of energy beam (e.g., lasing).
  • the gas stream(s) may be altered (e.g., reduced, or cease to flow) when the layer dispensing mechanism performs a dispensing of a layer of material (e.g., and exits the ancillary chamber).
  • the gas stream(s) may continue to flow when the layer dispensing mechanism performs a dispensing of a layer of material. Operation of the energy beam may comprise a dwell time of the energy beam.
  • the gas flow mechanism comprises laminar a flow at least within the (e.g., atmospheric) area of the processing cone (e.g., above the platform, Fig. 15, 1530).
  • the gas may flow in (e.g., substantial) at least two laminar streams while in the processing cone area.
  • the gas may flow in (e.g., substantially) laminar streams with in the processing cone.
  • Across the enclosure e.g., Fig.
  • the gas streams may flow in the same direction (e.g., from one side of the processing cone to the opposite side of the processing cone).
  • the flow across the depth and/or height of the processing cone may comprise a lateral flow.
  • the gas may flow in a smooth (e.g., and continuous) manner at least within the processing cone area.
  • the gas flow at least in the processing cone (e.g., in the processing chamber) may not comprise (i) recirculation of gas, (ii) gas flow stagnation, or (iii) static vortices, at least within the processing cone area.
  • In the processing chamber may comprise substantially in the entire processing chamber. Substantially is relative to the intended purpose of the 3D printer.
  • substantially in the entire processing chamber may exclude a volume of the processing chamber corner(s).
  • the gas may flow from one side of the processing chamber to the other side of the processing chamber, which gas flow travels at least through the processing cone, and/or has a flow velocity direction that is always unidirectional (e.g., does not change in direction or becomes stagnant).
  • the gas flow from one side of the processing chamber to the other side of the processing chamber.
  • the gas flow travels at least through the processing cone, has a flow velocity direction that is always positive (e.g., does not become negative or zero).
  • the magnitude and/or direction of the flow velocity can differ along the depth (e.g., Z direction) or height (e.g., Y direction) of the enclosure.
  • the magnitude of the flow velocity can differ along the width (e.g., X direction) of the enclosure.
  • the magnitude of the gas flow velocity along the depth, height and/or width of the enclosure may be (e.g., substantially) constant.
  • the direction of the gas flow velocity along the depth, height and/or width of the enclosure may be (e.g., substantially) constant.
  • the magnitude of the gas flow velocity along the depth, height and/or width of the enclosure may vary (e.g., linearly, or exponentially).
  • the variation may be a time variation (e.g., during the 3D printing, such as during the operation of the energy beam).
  • the variation may be a special variation (e.g., along the width, depth, and/or height of the enclosure).
  • Along the enclosure comprises along the processing cone.
  • the phrase “at least within the processing cone area of the enclosure” comprises at least within the atmospheric area above the platform (e.g., Fig. 15, 1530) and in the enclosure (e.g., Fig. 15, 1526). At least within the processing cone area of the enclosure may be disposed in the enclosure.
  • the enclosure may comprise a suction mechanism comprising a reduced pressure (e.g., vacuum duct).
  • the low- pressure duct(s) may be disposed adjacent to the platform and/or exposed surface of the material bed within the processing cone area.
  • the suction mechanism may at least remove a portion of debris (e.g., particulate material).
  • the suction mechanism may be activated when the energy beam is and/or is not projected towards the material bed.
  • the suction mechanism may be activated before, after, and/or during the 3D printing.
  • the suction mechanism may be activated during at least a portion of the 3D printing.
  • During at least a portion of the 3D printing may comprise during a transformation of a portion of the material bed, during the layer dispensing, or between the transformation and the layer dispensing.
  • the suction mechanism may be activated at a time when the gas streams in the enclosure cease to flow.
  • the gas flow mechanism comprises an inlet portion (e.g., Fig. 8, 840, 842, Fig. 9, 940, Fig. 12, 1235, Fig. 13, 1330), which can also be referred to as an inlet portion, gas inlet portion, gas inlet port, gas inlet portion, or other suitable term.
  • the inlet portion may be connected to a side wall of the enclosure (e.g., Fig. 8, 873).
  • the inlet portion (e.g., Fig. 12, 1235) may comprise one or more inlets (e.g., 1250).
  • the side wall may be an internal side wall (e.g., Fig. 9, 926).
  • the side wall may be a divider forming a processing chamber side wall (e.g., Fig. 12, 1236).
  • the inlet portion may include one or more openings (e.g., Fig. 9, 955, Fig. 12, 1250, 1252, 1255, Fig. 11 A, 1145, Fig. 11 B, 1155) to facilitate gas flow into the enclosure (e.g., into the inlet portion).
  • the inlet portion may be separated from the processing chamber by an internal inlet (e.g., separation) wall (e.g., 1236).
  • the aspect ratio of the internal inlet wall (e.g., 926) relative to an inlet opening (e.g., 955) can be at least about 500:1 , 250:1 , 200:1 , 100:1 , 50:1 , 25:1 or 10:1 .
  • the aspect ratio of the internal inlet wall (e.g., 926) relative to an outlet opening (e.g., 955) can be at most about 500:1 , 250:1 , 200:1 , 100:1 , 50:1 , 25:1 or 10:1 .
  • the aspect ratio of the internal inlet wall relative to an inlet opening can be between any of the afore-mentioned values (e.g., from about 500:1 to about 10:1 , from about 500:1 to about 100:1 , from about 100:1 to about 50:1 , or from about 50:1 to about 10:1).
  • the inlet portion is separated from the processing chamber by a filter (e.g., HEPA filter).
  • the filter may be one of the filters disclosed herein.
  • the outlet portion e.g., 1240
  • the processing chamber e.g., 1226
  • an internal outlet (e.g., separation) wall e.g. ,1237).
  • the internal outlet wall and/or internal inlet wall may comprise an opening.
  • the term “opening” may refer to the internal inlet wall opening, internal outlet wall opening, inlet opening, and/or outlet opening. Examples of internal wall openings can be seen in the examples in Figs. 7A-7B and Figs. 10A-10D.
  • the openings may be (e.g., reversibly) coupled to at least one side wall of the inlet portion. For example, one or more openings may be coupled to the same side wall.
  • the opening may be gas inlet opening that facilitate gas flow into the enclosure.
  • the opening may be gas outlet opening that facilitate gas flow out of the enclosure.
  • the multiple openings on the wall may be uniformly spaced horizontally, vertically and/or at an angle (e.g., 1250, 1252 and 1255).
  • the multiple openings may not be uniformly spaced.
  • the openings may run across the entire wall of the enclosure (e.g., height and/or depth thereof).
  • the openings may occupy a percentage of the enclosure height and/or depth (e.g., Fig. 10A). The percentage may be at least about 50%, 60%, 70%, 80%, 90%, 95%, 98% or 99% of the enclosure height and/or depth.
  • the openings may run across any number between the afore-mentioned heights and/or depths of the enclosure wall (e.g., from about 50% to about 99%, from about 50% to about 70%, from about 70% to about 90%, or from about 90% to about 99%).
  • the openings may be evenly or non-evenly spaced.
  • a greater concentration of openings may reside closer to the platform and/or exposed surface of the material bed (e.g., Fig. 7A, 751).
  • a lower concentration of openings may reside closer to the ceiling of the enclosure (e.g., Fig. 7A, 752).
  • a greater concentration of passable openings may reside closer to the platform and/or exposed surface of the material bed (e.g., Fig.
  • a lower concentration of closed openings may reside closer to the ceiling of the enclosure (e.g., Fig. 7B, 762).
  • the openings may extend from an exposed surface of the material bed and/or platform, to the optical window.
  • the openings may extend from an exposed surface of the material bed and/or platform, to at least 50%, 60%, 70%, 80%, 90%, 95%, 98%, or 99% height of the enclosure.
  • the openings extend from an exposed surface of the material bed and/or platform by any number between the aforementioned examples (e.g., from about 50% to about 99%, from about 50% to about 70%, from about 70% to about 90%, or from about 90% to about 99%).
  • the opening may be oval (e.g., Fig. 10D, 1040).
  • the opening may be circular (e.g., Fig. 10A, 1010).
  • the opening may be pipe shaped.
  • a cross section of the opening may be any geometrical shape (e.g., hexagonal, rectangular, square, circular or triangle).
  • a cross section of the openings may be random (e.g., Fig. 10D, 1041 ).
  • An opening may be a slit (e.g., Fig. 7C, 711).
  • the openings may comprise an array of openings (e.g., Fig. 10A).
  • the openings may comprise a single file of openings (e.g., Fig. 10C, including opening 1030).
  • the cross section of the openings may change its shape before, during, and/or after the 3D printing (or a portion thereof, e.g., during the operation of the energy beam).
  • the cross-sectional shape of the openings can be controlled (e.g., manually and/or by a controller).
  • the cross-sectional shape of the openings may be altered by the controller.
  • the alteration may comprise an electronic, magnetic, temperature, audio, or optical signal.
  • the alteration may be induced electronically, magnetically, by temperature alteration, audibly, optically, or by any combination thereof.
  • the alteration of at least two openings may be collectively (e.g., simultaneously or sequentially) controlled.
  • the alteration of at least two openings (e.g., within the array of openings) may be separately (e.g., individually) controlled.
  • the percentage of void forming the opening may be controlled before, during, and/or after the 3D printing (or a portion thereof, e.g., during the operation of the energy beam).
  • at least an opening may be closed (e.g., a line of openings, a plurality of opening, or the entire array).
  • Fig. 10D shows an example of a passable opening 1040 and a closed opening 1042.
  • the opening may have any opening values disclosed herein.
  • the opening can comprise sizes of at least about 0.1 millimeter (mm), 0.2 mm, 0.5 mm, 1 mm, 2 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, or 100 mm.
  • the opening can comprise sizes of at most about 0.1 millimeter (mm), 0.2 mm, 0.5 mm, 1 mm, 2 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, or 100 mm.
  • the opening can comprise sizes between any of the opening sizes disclosed herein.
  • the opening can comprise sizes from about 0.1 mm to about 100 mm, from about 5 mm to about 50 mm, or from about 50 mm to about 100 mm.
  • the inlet and/or outlet opening comprises a valve.
  • at least two openings may share the same valve.
  • at least two openings may have different valves.
  • the valve may control the flow of gas through the inlet opening. Control the flow may comprise flow velocity, pressure, gas content (e.g., oxidizing gas content), humidity content, gas make up.
  • the valve may be a mechanical, electrical, electro-mechanical, manually operable, controlled, or an automated valve.
  • the valve may comprise a pressure relief, pressure release, pressure safety, safety relief, pilot-operated relief, low pressure safety, vacuum pressure safety, low and vacuum pressure safety, pressure vacuum release, snap acting, or a modulating valve.
  • the valve may comply with the legal industry standards presiding the jurisdiction.
  • the inlet and/or outlet portion may comprise one or more ledges.
  • the ledge may control the amount and/or direction of gas flow into the enclosure (e.g., processing chamber).
  • the ledge may be pivotable (e.g., along a set of points on the edge) before, after, and/or during the 3D printing (or a portion thereof. For example, during the operation of the energy beam).
  • the ledge may be movable before, after, and/or during the 3D printing (or a portion thereof. E.g., during the operation of the energy beam).
  • the ledge may be retractable before, after, and/or during the 3D printing (or a portion thereof. E.g., during the operation of the energy beam).
  • the ledge may be controllable manually and/or automatically (e.g., using a controller).
  • the control may be before, after, and/or during the 3D printing (or a portion thereof. E.g., during the operation of the energy beam).
  • the amount and/or velocity of gas conveyed by the ledge may be controllable (e.g., in real time).
  • the ledge may be closable so that a reduced amount of gas will flow into the enclosure (e.g., no gas will flow into the enclosure).
  • the ledge may extend from one edge of the inlet and/or outlet opening space to the opposite edge of the inlet and/or outlet opening space respectively.
  • Fig. 12, 1240 shows an example of an outlet opening space.
  • the ledge may protrude from the gas inlets (e.g., 1250) towards the divider comprising the opening(s) (e.g., 1236).
  • the ledge may protrude from the divider comprising the opening(s) (e.g., 1236) towards the gas outlet (e.g., 1246).
  • the inlet portion comprises a perforated plate (a mesh, screen, e.g., Fig. 10A, Fig. 10C, Fig. 10D).
  • the internal inlet wall and/or internal outlet wall may comprise the perforated plate.
  • the inlet portion may comprise more than one perforated plates.
  • the multiple perforated plates may be stacked (e.g., vertically, horizontally, and/or at an angle).
  • the multiple perforated plates may be stacked in parallel to each other.
  • the perforated plate may comprise one or more perforations (e.g., Fig. 10A, 1010).
  • the perforation may be an opening (e.g., as disclosed herein).
  • the perforations may be uniformly spread across at least a portion (e.g., the entire) perforated plate.
  • Fig. 10A shows an example of uniform perforation spread across the entire perforated plate.
  • Fig. 7A shows an example of uniform perforation spread across a portion of the perforated plate (e.g., line numbers 1 to 3)
  • the perforated plate may comprise a single file (e.g., row) of perforations (e.g., Fig. 10C).
  • the size of the perforations in the plate may be uniform (e.g., Fig. 10A).
  • the size of the perforations in the plate may not be uniform (e.g., Fig. 10D, row number 5).
  • the angle of the perforations in the plate may not be uniform (e.g., Fig. 10D, row number 2). At times, the angle of the perforations in the plate may not be uniform (e.g., Fig. 10D, row number 7 or 3). At times, the pass-ability of the perforations in the plate may not be uniform (e.g., Fig. 10D, row number 2, wherein a black perforation designates a closed perforation, and a gray perforation represents an open perforation).
  • the size of the perforations may be controlled (e.g., as described herein re openings). For example, the perforations may be thermally controlled. The size of the perforations may contract with increase in surface temperature.
  • the size of the perforations may expand with a decrease in temperature.
  • the size of the openings (e.g., perforations) may be altered to control the amount and/or velocity of flow of gas through each opening. Altered may comprise increasing and/or decreasing the opening size.
  • the inlet and/or outlet portion comprises one or more ledges (e.g., Fig. 10B, 1020).
  • the ledges may be baffles.
  • the inlet and/or outlet portion may comprise a perforated plate or a ledge.
  • the inlet and/or outlet portion may comprise both a perforated plate and a ledge.
  • the ledge may be movable.
  • the ledge may be movable before, during, and/or after the 3D printing.
  • the ledge may be movable during a portion of the 3D printing. During a portion of the 3D printing may comprise during the operation of the energy beam, or during the formation of a layer of hardened material.
  • the ledge may be controlled manually and/or automatically.
  • the ledge may direct one or more streams of gas to flow in a certain direction.
  • the ledge may alter the amount and/or velocity of the gas stream.
  • the ledge may (e.g., substantially) prevent the gas flow through it by closing an opening.
  • the ledge may laterally extend from one edge of the intermediate wall to an opposing wall away from the processing chamber.
  • the opposing wall may comprise an inlet or outlet opening.
  • the ledge and/or opening may be passive.
  • the position (e.g., horizontal, vertical, and/or angular) of the ledges may be controlled (e.g., during at least a portion of the 3D printing).
  • the position of the ledge may be altered to control the amount, velocity, and/or direction of flow of at least one gas through each ledge.
  • Altered may comprise reducing gas flow (e.g., preventing).
  • Altered may comprise allowing gas flow.
  • the inlet portion comprises a geometric shape (e.g., rectangular shape, square shape, circular shape, box shape).
  • Fig. 8 shows an example of inlet portions, e.g., 840, 842.
  • Fig. 12 and Fig. 13 show an example of an inlet portion, e.g., 1235, 1335.
  • Components of Fig. 13 can be disposed relative to gravitational vector 1399 pointing to gravitational center G
  • components of Fig. 12 can be disposed relative to gravitational vector 1299 pointing to gravitational center G.
  • the inlet portion may be aerodynamically shaped (e.g., wind tunnel shape, tubular shape, rain drop shape, rocket shape).
  • the aerodynamic shape may enable smooth flow of gas through the inlet portion.
  • the aerodynamic shape may prevent the formation of standing vortices, cyclones, and/or stagnant gas.
  • Fig. 9 shows an example of an inlet portion having an aerodynamic shape 940.
  • the aerodynamic shape may initiate from at least one (e.g., narrow) opening (e.g., Fig. 9, 955) distant from the processing chamber (e.g., Fig. 9, 901).
  • Components of Fig. 9 can be disposed relative to gravitational vector 999 pointing to gravitational center G.
  • Components of Fig. 8 can be disposed relative to gravitational vector 899 pointing to gravitational center G.
  • the acute angle of the average aerodynamic shape plane e.g., Fig.
  • the acute angle of the average aerodynamic shape plane relative to the floor of the processing chamber can be at most about, 20 °, 30 °, 40 °, 42°, 45 °, 50 °, 60 °, 70 °, or 80 °.
  • the acute angle of the average aerodynamic shape plane shape relative to the floor of the processing chamber can be between any of the afore-mentioned values (e.g., from about 20° to about 80°, from about 20° to about 40°, from about 40° to about 60 °, or from about 60° to about 80°).
  • the aerodynamic shape may comprise a pyramidal, or a conical 3D shape.
  • the inlet portion may comprise one or more baffles (e.g., Fig. 13, 1360).
  • a baffle, as understood herein, may be a device used to restrain and/or deflect the flow of gas. The baffle may be placed after an inlet opening (e.g., Fig. 13, 1360).
  • the baffle may be placed within an inlet portion (e.g., Fig. 13, 1360).
  • the baffle may be placed at a location within the processing chamber.
  • the baffle may be placed at a location within the enclosure (e.g., Fig. 9, 965, 970).
  • the baffle may comprise indentations.
  • the indentations may form a pattern.
  • the indentation may facilitate directing the gas flow.
  • the baffle may comprise one or more openings (e.g., as disclosed herein).
  • the size of the perforations may be uniform or non-uniform.
  • the size of the perforations may be controlled.
  • the baffle may be a deflector.
  • the deflector may be a gas (e.g., wind) deflector.
  • the deflector may aid in directing the glow of gas.
  • the deflector may redirect the flow of gas.
  • the deflector may be a screen.
  • the deflector may be a shield.
  • the gas flow mechanism comprises an outlet portion (e.g., Fig. 8, 870, Fig. 9, 945, Fig. 12, 1245, Fig. 13, 1345), which can also be referred to as an outlet portion, gas outlet port volume, gas outlet volume, gas outlet portion, or other suitable term.
  • the gas outlet portion may have similar structure and/or apparatuses to the gas inlet portion.
  • the outlet portion may be connected (e.g., reversibly) to a side wall of the enclosure.
  • the outlet portion may be connected (e.g., reversibly) to a first side wall that opposes a second side wall that is coupled to the inlet area.
  • the outlet portion can include one or more outlet openings (e.g., Fig.
  • the one or more outlet openings may be coupled (e.g., reversibly) to at least one side wall of the outlet portion.
  • the multiple openings may or may not be uniformly spaced.
  • the outlet openings may run across the entire wall of the enclosure (e.g., horizontally, vertically, and/or at an angle).
  • the outlet openings may occupy a percentage of the enclosure height and/or depth. The percentage may be at least about 50%, 60%, 70%, 80%, 90% or 95% of the enclosure height and/or depth.
  • the outlet openings may be evenly or non-evenly spaced.
  • the openings may run across any number between the afore-mentioned heights and/or depths of the enclosure wall (e.g., from about 50% to about 99%, from about 50% to about 70%, from about 70% to about 90%, or from about 90% to about 99%).
  • a greater concentration of outlets may reside closer to the platform and/or exposed surface of the material bed.
  • a lower concentration of outlet openings may reside closer to the ceiling of the enclosure.
  • the outlet openings may extend from an exposed surface of the material bed and/or the platform to the optical window.
  • the outlet openings may extend from an exposed surface of the material bed and/or platform to at least about 50%, 60%, 70%, 80%, 90% 95%, 98%, or 99% height and/or depth of the enclosure.
  • the openings extend from an exposed surface of the material bed and/or platform by any number between the afore-mentioned examples (e.g., from about 50% to about 99%, from about 50% to about 70%, from about 70% to about 90%, or from about 90% to about 99%).
  • the outlet opening may be any opening disclosed herein.
  • the center of the inlet opening and/or outlet opening are disposed in an enclosure wall (e.g., side wall, e.g., Fig. 8, 873) in a position.
  • That position can be of at least about 1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60% of the enclosure side wall relative to the bottom of the processing chamber (e.g., comprising the exposed surface of the material bed and/or platform), wherein the percentage is along the Y direction (wall height).
  • That position can be of at most about 1%, 2%, 5%,
  • the enclosure side wall relative to the bottom of the processing chamber (e.g., comprising the exposed surface of the material bed and/or platform) wherein the percentage is along the Y direction (wall height). That position can be between any of the afore-mentioned values the enclosure side wall relative to the bottom of the processing chamber (e.g., from about 1% to about 60%, from about 1% to about 25%, from about 30% to about 45%, or from about 45% to about 60% from the material bed).
  • That position can be of at least about 1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60% of the enclosure wall relative to a frontal wall of the processing chamber (e.g., perpendicular to the bottom of the processing chamber and to the enclosure sidewall), wherein the percentage is along the Z direction (wall depth).
  • That position can be of at most about 1%, 2%, 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60% of the enclosure wall relative to a frontal wall of the processing chamber (e.g., perpendicular to the bottom of the processing chamber and to the enclosure side wall), wherein the percentage is along the Z direction (wall depth).
  • That position can be between any of the afore-mentioned values the enclosure side wall relative to the frontal wall of the processing chamber (e.g., from about 1% to about 60%, from about 1% to about 25%, from about 30% to about 45%, or from about 45% to about 60% from the material bed).
  • Fig. 11 A shows an example of a side enclosure wall 1140 comprising an opening 1145 that is partially obstructed by a baffle 1143. A center of the opening 1145 is disposed at about 25% of the enclosure side wall height 1142 relative to the bottom of the processing chamber, and at about 50% depth 1141 from a frontal enclosure wall.
  • Fig. 11 B shows an example of a side enclosure wall 1150 comprising an unobstructed opening 1155.
  • the outlet portion comprises one or more ledges.
  • the ledge may be any ledge disclosed herein.
  • the ledge may be (e.g., laterally) extending from one edge of the outlet portion (e.g., comprising the outlet opening, e.g., 872) to the opposite edge of the outlet portion (e.g., to the internal outlet wall, e.g., 871).
  • the outlet portion may comprise an internal outlet wall (e.g., 871 ).
  • the internal outlet wall may be any internal wall described herein.
  • the aspect ratio of the internal outlet wall relative to an outlet opening can be at least about 500:1 , 250:1 , 200:1 , 100:1 , 50:1 , 25:1 or 10:1 .
  • the aspect ratio of the internal outlet wall relative to an outlet opening can be at most about 500:1 ,
  • the aspect ratio of the internal outlet wall relative to an outlet opening can be between any of the afore-mentioned values (e.g., from about 500:1 to about 10:1 , from about 500:1 to about 100:1 , from about 100:1 to about 50:1 , or from about 50:1 to about 10:1).
  • the internal outlet wall may comprise a perforated plate.
  • the perforated plate may be any perforated plate described herein. In some instances, the outlet portion may comprise more than one perforated plate.
  • the multiple perforated plates may be stacked (e.g., vertically, horizontally and/or at an angle).
  • the multiple perforated plates may be stacked parallel to each other.
  • the perforations may be any perforation disclosed herein.
  • the plurality of perforated plates may comprise 2, 3, 4, 5, 6, 7, 8, 9, or 10 perforated plates (e.g., through which the gas flows prior to entry into the processing chamber).
  • the perforated plate may be heated and/or cooled.
  • the temperature of the gas flow may be regulated using the perforated plate.
  • the perforated plate(s) may be operatively coupled to a heat exchanger and/or heat source.
  • the collective respective cross sectional area of the holes in the perforated plates can be the (e.g., substantially) same as the respective cross sectional collective areas of the gas entrance openings.
  • the speed along the (e.g., entire) height of the processing chamber and/or cone is (e.g., substantially) constant.
  • the speed along the (e.g., entire) height of the processing chamber and/or cone may vary.
  • the speed may vary gradually or non-gradually (e.g., using one or more horizontal partitions).
  • the perforated plate can comprise space filling polygonal openings (e.g., having hexagonal, or rectangular cross section).
  • the perforated plate(s) may comprise a separator, diffuser, and/or collimator (e.g., having a cross section of a geometric shape as described herein).
  • the collimator may comprise an aligning passage (e.g., channel).
  • the polygons can be any polygons describe herein as suitable.
  • the space filling polygon arrangement may be planar (e.g., in a single plane).
  • the space filling polygon arrangement may comprise a tessellation.
  • the tessellation may comprise a (e.g., symmetric) polygon.
  • the tessellation may comprise an equilateral polygon.
  • the tessellation may comprise a triangle, tetragon (e.g., quadrilateral), or hexagon.
  • the tetragon may comprise a concave or convex tetragon.
  • the tetragon may comprise a rectangle.
  • the rectangle may comprise a square.
  • the perforated plate and/or cross section of the collimator e.g., aligning passage(s)
  • the oval may comprise a circle.
  • the cross-section of the aligning passage and/or perforated plate hole may be a square, rectangle, triangle, pentagon, hexagon, heptagon, octagon, nonagon, octagon, circle, icosahedron, or any combination thereof.
  • a cross section of the outlet portion is of a geometric shape (e.g., rectangular shape, square shape, circular shape, box shape).
  • Fig. 12 and Fig. 13 show an example of an outlet portion, e.g., 1240, 1340.
  • the outlet portion may be aerodynamically shaped (e.g., wind tunnel shape, tubular shape, rain drop shape, rocket shape).
  • the aerodynamic shape may enable smooth flow of gas through the outlet portion.
  • the outlet portion can have a cross-section shape that tapers toward an outlet opening (e.g., 872).
  • the aerodynamic shape may converge into at least one (E.g., narrow) opening before exiting the enclosure.
  • the aerodynamic shape may facilitate decrease in (e.g., elimination of) gas recirculation, static vortices and/or stagnated flow of gas, at least within the processing cone (e.g., within the enclosure).
  • the outlet portion comprises one or more baffles (e.g., Fig. 9,
  • the baffle may be placed between the outlet opening and the processing chamber.
  • the baffle may be placed within an outlet portion. There may be one or more baffles within the outlet portion.
  • the baffle may be any baffle disclosed herein.
  • the gas flow mechanism is coupled to a recycling mechanism.
  • the recycling mechanism may comprise a closed loop system.
  • the recycling mechanism may collect the gas from the outlet portion (e.g., 870) and/or from the outlet opening (e.g., 872).
  • the recycling mechanism may filter the gas.
  • the recycling mechanism may inject the gas into the enclosure.
  • the recycling mechanism may inject the gas into the inlet opening (e.g., 955), inlet portion (e.g., 940), and/or processing chamber (e.g., 901).
  • the injection may be direct or indirect. At least a portion of the recycling may be performed before, after, and/or during the 3D printing.
  • the recycling mechanism may comprise a filtering mechanism (e.g., Fig. 8, 830, Fig. 14, 1460).
  • the recycling mechanism may comprise a device configured to remove the debris (e.g., particulate material) from the gas.
  • the removal may be using a filter, screen, perforated-plate, or any combination thereof.
  • the removal may be using a charge such as a magnetic and/or electrical charge.
  • the removal may comprise using an electrostatic gas filter.
  • the filtering mechanism may comprise a filter (e.g., polymer, HEPA, polyester, paper, mesh, or electrostatic gas filter). The filter may enable a gas to flow through it.
  • the filter may prevent the debris from flowing through it.
  • the filtering mechanism may allow gas to flow through.
  • the filtering mechanism may separate the gas from debris (such as particulate material, and/or soot) behind.
  • the filtering mechanism may comprise a filter, an outlet opening, inlet opening, canister, channel, sensor, or valve.
  • the filtering mechanism may comprise a pressure difference mechanism to filter gas from the debris.
  • the filtering mechanism may comprise a gas removal mechanism (e.g., vacuum, or gas channel).
  • the suction mechanism may comprise a filter.
  • the recycling and/or suction mechanism may facilitate (e.g., evacuate and/or channel) a flow of the gas from the outlet opening to the inlet portion (e.g., through the inlet opening).
  • the gas from the outlet opening may be conveyed via the filtering mechanism (e.g., using positive or negative pressure, for example, using a gas pump).
  • the filtering mechanism may be continuously operational during at least a portion of the 3D printing (e.g., during the operation of the energy beam, during formation of a layer of hardened material, during deposition of a layer of pre-transformed material, during the printing of the 3D object).
  • the filtering mechanism may be controlled (e.g., before, after, and/or during at least a portion of the 3D printing).
  • the control may be manual and/or automatic.
  • the filtering mechanism may comprise a paper, mesh, or an electrostatic filter.
  • the filtering mechanism may include one or more sensors (e.g., optical, pressure).
  • the sensors may detect incoming gas into the filtering mechanism.
  • the sensors may detect debris in the filter.
  • the sensors may detect clogging of the filter.
  • the filtering mechanism may be done in batches and/or continuously.
  • the filtering mechanism may operation during at least a portion of the 3D printing.
  • the recycling mechanism and/or suction mechanism may release the gas into the filtering mechanism in batches.
  • the release of gas may be timed.
  • the recycling mechanism may comprise a pump.
  • the filtering mechanism may be operatively coupled (e.g., connected) to the pump (e.g., Fig. 8, 835, Fig. 14, 1450).
  • the pump may receive a filtered gas from the filtering mechanism.
  • the pump may be coupled to a variable frequency drive.
  • the variable frequency drive may allow controlling the gas flow rate from the pump (e.g., into the enclosure). At times, the gas flow rate may be dynamically (e.g., real time) controlled.
  • the control may be manual and/or automatic.
  • the recycling mechanism may comprise a re-conditioning system.
  • the re-conditioning system may recondition the gas (e.g., remove any reactive species such as oxidizing gas, or water).
  • the re-conditioned gas may be recycled and used in the 3D printing. Recycling may comprise transporting the gas to the processing chamber. Recycling may comprise transporting the gas to the inlet portion. Recycling may comprise transporting the gas within the enclosure (e.g., Fig. 14, 1440, Fig. 1 , 100).
  • the re-conditioning mechanism may recondition the separated pre-transformed material that may be residual from the filtering mechanism.
  • the residual material may be filtered and/or collected in a separate container (e.g., Fig. 8, 838).
  • the re-conditioned material may be recycled and used in the 3D printing. Recycling may comprise transporting the material to the layer dispensing system. The recycling may be continuous and/or in batches during at least a portion of the 3D printing.
  • the recycling mechanism may be coupled to a sieve (e.g., filter).
  • gas material may be sieved before recycling and/or 3D printing.
  • Sieving may comprise passing a gas borne material (e.g., liquid or particulate) through a sieve.
  • the sieving may comprise passing the gas borne material using a flow of the gas, through a cyclonic separator.
  • Sieving may comprise classifying the gas borne material.
  • Classifying may comprise gas classifying.
  • Gas classifying may comprise air- classifying.
  • Gas classifying may include transporting a material (e.g., particulate material) through a channel.
  • a first set of gas flow carrying particulate material of various types e.g., cross sections, or weights
  • a second set of gas flow may flow vertically from a first vertical side of the channel to a second vertical side.
  • the second vertical side of the channel may comprise material collectors (e.g., bins).
  • material collectors e.g., bins.
  • the particulate material may travel to the material collectors, depending on their size and/or weight, such that the lighter and smaller particles collect in the first collator, and the heaviest and largest particles collect at the last collector. Blowing of gas (e.g., air) may allow classification of the particulate material according to the size and/or weight.
  • the material may be conditioned before use (e.g., re-use) within the enclosure.
  • the material may be conditioned before, or after recycling.
  • a filtering mechanism may be operatively coupled to at least one component of the layer dispensing mechanism, the pump (e.g., pressurizing pump), an ancillary chamber and/or the processing chamber.
  • the filtering mechanism may be operatively coupled to the gas flow mechanism.
  • the filtering mechanism may be operatively coupled (e.g., physically coupled) to the gas conveying channel of the gas flow mechanism.
  • Physically coupled may comprise fluidly coupled to allow at least flow of a gas (e.g., and gas borne material).
  • Operatively coupled may include fluid communication (e.g., a fluid connection, and/or a fluid conveying channel).
  • Fluid communication may include a connection that allows a gas, liquid, and/or solid (e.g., particulate material) to flow through the connection.
  • the filtering mechanism may be operatively coupled to an outlet portion of the processing chamber.
  • a gas comprising gas-borne materials e.g., debris, soot, reactive species, and/or pre-transformed material
  • the filtering mechanism may be configured to facilitate separation of the gas-borne materials from gas.
  • the filtering mechanism may comprise one or more filters or pumps.
  • the one or more filters may comprise crude filters or fine filters (e.g., HEPA filters).
  • the one or filters may be disposed before a pump and/or after a pump. Fig.
  • FIG. 17 shows an example of a filtering mechanism comprising two filters 1705 and 1702 disposed before the pump 1715, and a filter 1703 disposed after the pump, wherein before and after is relative to the direction of gas flow into the processing chamber 1720.
  • the filtering mechanism may be (e.g., further) facilitate flow of gas into the processing chamber through an inlet portion.
  • Fig. 17 schematically shows an example of a filtering mechanism.
  • the filtering mechanism may be operatively coupled to a processing chamber (e.g., 1720), and/or to an ancillary chamber (e.g., 1765) through one or more gas conveying channels (e.g., 1725, or, 1730) and/or through one or more valves (e.g., 1735, 1740, 1745, 1750, 1770, 1772, 1774, 1776, and/or 1735).
  • the valves may be controlled.
  • the control may be manual and/or automatic.
  • the control may be before, after, and/or during the 3D printing.
  • the valve may facilitate engagement and/or dis-engagement of one or more segments of the 3D printer (e.g., one or more segments of the gas flow mechanism).
  • the valve may facilitate engagement and/or dis-engagement of a filtering mechanism with the pump and/or the processing chamber.
  • the valve may facilitate insertion of gas into one or more segments of the 3D printer.
  • the valve e.g., 1770, 1772
  • the valve may facilitate insertion of gas into the filtering mechanism.
  • the valve may facilitate discharge of gas from one or more segments of the 3D printer.
  • the valve e.g., 1774, 1776) may facilitate discharge of a gas from the filtering mechanism.
  • One or more sensors may sense a condition and/or a physical property (e.g., atmosphere, pressure, filtering mechanism presence (e.g., when one or more filters is present), gas flow, amount of gas borne material, and/or mass flow) within the one or more segments of the 3D printer (e.g., the filtering mechanism).
  • the filtering mechanism may be operatively coupled to a pump (e.g., 1715).
  • the pump may induce gas flow in one or more segments of the 3D printer.
  • the pump may induce gas flow (e.g., gas circulation) within the processing chamber and/or the filtering mechanism.
  • the filtering mechanism is configured to provide filtered gas to an optical window purging system (e.g., 1701), examples of which are described herein.
  • the filtering mechanism comprises one or more canisters (e.g., 1705, 1710).
  • the canister may comprise a uniform or a non-uniform shape.
  • the canister may comprise a geometrical shape (e.g., a cylinder, sphere, rectangular, and/or circular).
  • the canister may comprise a 3D shape.
  • the canister may have an internal and/or external 3D shape.
  • the internal shape may be the same or different as the external 3D shape of the canister.
  • the canister may have a uniform or a non-uniform internal 3D shape.
  • the 3D shape may comprise a cuboid (e.g., cube), a tetrahedron, a polyhedron (e.g., primary parallelohedron), at least a portion of an ellipse (e.g., circle), a cone, a triangular prism, hexagonal prism, cube, truncated octahedron, or gyrobifastigium, a pentagonal pyramid, or a cylinder.
  • the polyhedron may be a prism (e.g., hexagonal prism), or octahedron (e.g., truncated octahedron).
  • a vertical cross section (e.g., side cross section) of the 3D shape may comprise a circle, triangle, rectangle (e.g., square, e.g., 1820, 1825), pentagon, hexagon, octagon, or any other polygon.
  • the vertical cross section may be of an amorphous shape.
  • the polygon may comprise at least 3, 4, 5, 6, 7, 8, 9, or 10 faces.
  • the polygon may comprise at least 3, 4, 5, 6, 7, 8, 9, or 10 vertices.
  • the cross-section may comprise a convex polygon.
  • the polygon may be a closed polygon.
  • the polygon may be equilateral, equiangular, regular convex, cyclic, tangential, edge-transitive, rectilinear, or any combination thereof.
  • the (e.g., vertical) cross-section of the 3D shape may comprise a square, rectangle, triangle, pentagon, hexagon, heptagon, octagon, nonagon, octagon, circle, or icosahedron.
  • the canister may be replaceable, removable, exchangeable, and/or modular.
  • the canister may be removed, replaced, and/or exchanged before, during, and/or after 3D printing. Removing, replacing, and/or exchanging may be done manually and/or automatically (e.g., using at least one controller, controlled, and/or semi-automatic).
  • the canister may comprise a material that facilitates entrapment of the gas borne material and/or internal 3D printer gas (e.g., inert gas).
  • the canister may comprise a material that facilitates impermeability of an external gas (e.g., air, oxidizing gas, water, and/or humidity) into the canister. External may include an atmosphere on the exterior of the canister.
  • the canister may comprise a material that facilitates minimal gas and/or liquid leaks.
  • the material of the canister may facilitate adherence to safety standard prevailing in the jurisdiction, for example, by limiting the oxidizing gas and/or humidity concentration in the canister (e.g., during and/or after the filtering process). The limit may be based on the standard in the jurisdiction.
  • Example standards may include combustion and/or ignition related standard, fire related standard (e.g., American Society for Testing and Materials International (ASTM), Occupational Safety and Health Administration (OSHA), Hazard Communication Standard (HCS), Material Safety Data Sheet (MSDS), and/or National Fire Protection Association (NFPA)).
  • the canister may comprise a partition (e.g., a wall) between one or more internal surfaces (e.g., solid material surface).
  • the partition may form a gap (e.g., a void).
  • the gap may be between a first internal surface and a second internal surface of the canister.
  • the gap may be filled with a gas.
  • the gap may be filled with a material different than the material of the internal surface of the canister (e.g., a liquid, semi-solid, and/or solid material).
  • the gas may comprise an atmosphere.
  • the atmosphere of the gap may facilitate maintaining the atmosphere of the canister to (e.g., substantially) prevent an atmospheric leak (e.g., permeation of gas such as an oxidizing gas, reactive agent, and/or water).
  • the atmosphere of the gap may be different than the atmosphere of the canister interior.
  • the canister may facilitate containing gas-borne material (e.g., debris, soot, pre-transformed material, and/or reactive species), for example, in an atmosphere that does not react with the gas borne material.
  • the gas-borne material may be deposited within the canister (e.g., adhering to a filter) as a result of filtering the gas (e.g., of flowing the gas) from the processing chamber.
  • the canister e.g., a surface of the canister
  • the valve may allow a flow of gas into and/or out of the canister.
  • the canister may comprise an entrance opening and an exit opening. The exit opening and the entrance opening may be in opposing sides of the canister. In some embodiments, the exit opening and the entrance opening to the canister may be disposed on non-opposing sides of the canister, for example, on adjacent sides of the canister.
  • the valve may connect the canister to a processing chamber, a member of the layer dispenser, an ancillary chamber, a control system, and/or a pump.
  • the valve may be any valve disclosed herein.
  • the canister comprises a filter (e.g., a sieve, screen, a perforated plate and/or baffle).
  • the filter may be configured to separate the gas-borne material from the gas.
  • the filter may be located within an interior of the canister.
  • the filter may be disposed adjacent to (or connected, and/or operatively coupled to) one or more internal surfaces (e.g., walls) of the canister.
  • the filter may comprise a material that facilitates maintenance of an atmosphere within the canister.
  • the filter may not expel the reactive agent (or precursors thereof).
  • the filter may not expel an oxidizing gas and/or humidity (or precursors thereof).
  • Example filters include a composite material, a fiber media, a paper pulp, a fiber gas, polymer, HEPA, polyester, paper, mesh, polymeric, or electrostatic gas filter.
  • the filter may be cleaned. Cleaning may be done before, during, and/or after 3D printing. Cleaning may comprise isolating the canister from the 3D printer (e.g., from the gas flow mechanism). Cleaning may include drenching (e.g., with water, liquid, and/or gas). The liquid may comprise a hydrophilic and/or hydrophobic substance and/or solution. The hydrophilic substance may comprise water. The hydrophobic substance may comprise oil. Cleaning may require removal of the canister comprising the filter. In some embodiments, the cleaning may be performed without removal of the canister comprising the filter. In some embodiments, cleaning may require removal of the filter from the 3D printer and/or from the canister. In some embodiments, the cleaning may be performed without removal of the filter from the canister.
  • the canister comprises an inlet portion and/or an outlet portion.
  • the inlet portion and/or outlet portion may facilitate reconditioning (e.g., cleaning) of the filter.
  • the inlet portion may be located adjacent to a top surface of the canister. Top may be in a direction away from the platform and/or against the gravitation center.
  • the inlet may comprise an inlet channel (e.g., pipe, tube, and/or canal). The inlet may allow insertion of a cleaning material.
  • the inlet channel may extend to a location adjacent to a surface (e.g., top) of the filter.
  • the outlet portion may be in an opposite side of the canister where the inlet is located.
  • the outlet may be located on a side of the inlet that is different from the side opposing the inlet. In some embodiments, the outlet does not oppose the inlet. For example, the outlet may not directly oppose the inlet. For example, the outlet may be located adjacent to a side surface of the canister. Adjacent to a side surface may comprise in a direction perpendicular and/or at an angle to the inlet. If the inlet is disposed along a vertical line (e.g., along the gravitational vector), the outlet may be disposed at an angle relative to the vertical line.
  • a vertical line e.g., along the gravitational vector
  • the outlet portion may be at an acute angle at least about 1°, 2°, 5°, 10°, 20°, 30°, 40°, 45°, 50°, 60°, 70°, 80°, or 90° with respect to the vertical line.
  • the outlet portion may be at an acute angle at most about 1°, 2°, 5°, 10°, 20°, 30°, 40°, 45°, 50°, 60°, 70°, 80°, or 90° with respect to the vertical line.
  • the outlet portion may be at an acute angle between any of the afore-mentioned acute angle values with respect to the vertical line, for example, from about 1°to 90°, or from about 1°to about 30°, from about 30° to about 60°, or from about 60° to about 90°.
  • the outlet portion may facilitate reconditioning (e.g., refurbishing) of the filter, for example, by separation of the gas borne material that adheres to the filter during the filtering operation (e.g., during gas circulation through the canister).
  • the separation may be facilitated by a cleansing material comprising a gas and/or a liquid.
  • the cleansing material may be a non-reactive, and/or inert to the gas-borne material.
  • the outlet portion may facilitate cleansing of the filter, for example, by flowing off gas borne material that is adheres to (e.g., collected on/in) the filter.
  • the outlet portion may comprise an outlet channel.
  • the outlet channel may facilitate the flow of the gas borne material from the filter to an area (e.g., collection area) outside the canister.
  • the filtering mechanism comprises one or more valves (e.g., flow, stopper, pressure, engaging, dis-engaging, and/or control valve).
  • the valve may allow gas, liquid, and/or solid to (e.g., controllably) flow through.
  • the solid may comprise a particulate material.
  • the valve may allow gas, liquid, and/or solid to (e.g., controllably) prevent from flowing through.
  • valves include a pressure relief, pressure release, pressure safety, safety relief, pilot-operated relief, low pressure safety, vacuum pressure safety, low and vacuum pressure safety, pressure vacuum release, snap acting, pinch, metering, flapper, needle, check, control, solenoid, flow control, butterfly, ball, piston, plug, popping, rotary, manual, or modulating valve.
  • the filtering mechanism comprises one or more sensors (e.g., presence, mass flow, pressure, temperature, atmosphere, humidity, oxidizing gas, gas, flow, velocity, material density, detection, clogging detection, and/or level sensor).
  • the sensor may sense the level of reactive gas.
  • the reactive gas may comprise oxygen, water, carbon dioxide, or nitrogen.
  • the reactive gas may react with the material used or produced during the 3D printing.
  • the material produced during the 3D printing may comprise debris, or soot.
  • the material used for the 3D printing may comprise a particulate material (e.g., powder).
  • the sensor may detect at least one characteristic of the gas that flows through a filter within the canister.
  • the at least one gas characteristic may comprise gas type, reactive gas level, temperature, pressure, or flow rate.
  • the sensor may detect a presence of a canister in the gas flow mechanism.
  • the sensor may detect a presence of a filter in the filtering mechanism (e.g., in the canister).
  • the sensor may detect at least one gas characteristic of an atmosphere within the canister.
  • the at least one characteristic of the atmosphere may comprise gas type, reactive gas level, temperature, pressure or flow rate.
  • the sensor may send a signal to one or more controllers operatively coupled to the filtering mechanism.
  • the sensors may detect a state of at least one component of the filtering mechanism, for example, a level of clogging of the filter, the number of canisters present in the gas flow mechanism (as part of the filtering mechanism), the number of canisters engaged and/or disengaged from the gas flow mechanism, and/or the number of canister in use.
  • the controller may adjust one or more physical properties (e.g., flow of gas, pressure, velocity, temperature, reactive agent level, and/or atmosphere) of the filtering mechanism (e.g., based on a sensor signal).
  • the controller may adjust a flow of gas in the gas flow mechanism (e.g., based on the amount of clogging within the filter in the canister).
  • the controller may adjust a flow of gas in the filtering mechanism and/or the processing chamber (e.g., based on the amount of clogging within the filter in the canister).
  • the controller may adjust the flow of gas to maintain a desired and/or requested gas flow velocity and/or acceleration.
  • the control may be performed before, after, and/or during 3D printing.
  • the control may be manual and/or automatic.
  • the filtering mechanism comprises one or more indicators (e.g., visual, sound, and/or tactile).
  • the indicator may alert one or more human senses (e.g., sound, visual, tactile, oral, and/or olfactory).
  • the indicators may be a part of a user interface, and/or touchscreen.
  • the indicator may comprise an optical signal.
  • the indicators may reflect a state of the filtering mechanism.
  • the state of the filtering mechanism may include sensing a signal from one or more sensors.
  • Example states of the filtering mechanism may include in a safe to use, ready to use, in operation, unsafe to use, safe to change filter, and/or unsafe to change filter.
  • the safety indicators may correspond to the safety standards in the jurisdiction.
  • the 3D printing system comprises multiple (e.g., two) filtering mechanisms.
  • Fig. 18 schematically shows an example of two filtering mechanisms (e.g.,
  • the one or more filtering mechanism may be operatively coupled to the processing chamber (e.g., 1810)
  • a first filtering mechanism may be coupled to the processing chamber.
  • a second filtering mechanism may be coupled to the processing chamber.
  • multiple (e.g., two, three, four, and/or five) filtering mechanisms may be coupled to the processing chamber.
  • the gas conveying channel may comprise a valve (e.g., 1835). The valve may facilitate reversibly connecting the first filtering mechanism and/or the second filtering mechanism to the processing chamber (e.g., during, before and/or after the 3D printing).
  • a filtering mechanism may comprise one or more (e.g., two) canisters (e.g., 1820 and 1825).
  • a first canister may be coupled to the processing chamber.
  • a second canister may be coupled to the processing chamber.
  • the plurality (e.g., two, three, four, and/or five) of canisters may be coupled to the processing chamber.
  • the multiple filtering mechanisms may facilitate a continuous filtering of the gas that flows within at least the processing chamber (e.g., the gas that flows within the gas circulation mechanism comprising the processing chamber, ancillary chamber, a component of the layer dispenser or a pump), which continuous filtering is before, after and/or during the 3D printing.
  • the plurality of filtering mechanisms may facilitate an exchange of at least one filter during the continuous filtering of the gas that flows within at least a portion of the gas circulation system (e.g., the processing chamber), which continuous filtering is before, after and/or during the 3D printing.
  • the canisters may facilitate maintaining a requested amount of a physical property of gas within the processing chamber and/or ancillary chamber.
  • the requested amount of the physical property of the gas may be pre-determined and/or constant.
  • the physical property of the gas may comprise a density, velocity, type, and/or acceleration.
  • the physical property of the gas may comprise an amount (e.g., contamination) of a reactive agent in the gas.
  • the reactive agent may comprise an oxidizing agent.
  • the multiple filtering mechanisms may facilitate maintaining a constant and/or diminished amount of gas-borne material in the processing chamber and/or ancillary chamber.
  • the continuous filtering may comprise alternating filtering from a first filtering mechanism and a second filtering mechanism.
  • the continuous filtering may comprise alternating the gas flow from flowing through a first canister (comprising a first filter) to flowing through a second canister (comprising a second filter).
  • Alternating may comprise switching filtering from a first filtering mechanism to a second filtering mechanism. Switching may be done before, during, and/or after 3D printing. Switching may be controlled (e.g., manually or automatically using a controller).
  • Alternating may comprise dis-engaging a first filtering mechanism (e.g., comprising the canister, valve, channel, sensor, or filter). Alternating may comprise engaging a second filtering mechanism (e.g., comprising the canister, valve, channel, sensor, or filter). Alternating may comprise controlling one or more valves. Alternating may comprise detecting a status of the first filtering mechanism and/or second filtering mechanism, for example, by reading signals from one or more sensors.
  • a first filtering mechanism e.g., comprising the canister, valve, channel, sensor, or filter
  • Alternating may comprise engaging a second filtering mechanism (e.g., comprising the canister, valve, channel, sensor, or filter).
  • Alternating may comprise controlling one or more valves. Alternating may comprise detecting a status of the first filtering mechanism and/or second filtering mechanism, for example, by reading signals from one or more sensors.
  • the alternating process may comprise (i) sensing a physical property (e.g., clogging, gas velocity, rate of gas flow, direction of gas flow, rate of mass flow, direction of mass flow, temperature, reactive agent level, and/or gas pressure) of flowing gas within a first filtering mechanism, (ii) sensing a presence of a second filtering mechanism (e.g., using a presence sensor), (iii) sensing an atmosphere and/or a physical property (e.g., reactive agent, pressure, humidity and/or temperature) of the second filtering mechanism,
  • a physical property e.g., clogging, gas velocity, rate of gas flow, direction of gas flow, rate of mass flow, direction of mass flow, temperature, reactive agent level, and/or gas pressure
  • At least two of operations (i) - (vii) may be performed sequentially.
  • Reconditioning the first filtering mechanism may comprise removing the filter from the canister within the filtering mechanism.
  • Reconditioning the first filtering mechanism may comprise drenching the filter within the canister.
  • Drenching may comprise inserting a cleaning material (e.g., liquid, gas, semi-solid, and/or any other cleaning medium) into the filter. Drenching may be performed before, after, or during removal of the filter from the canister. Drenching may be performed before, after, or during the 3D printing.
  • Replacing the first filtering mechanism may be performed when the second filter mechanism is in operation (e.g., during the 3D printing). Replacing may comprise replacing a canister. Replacing may comprise replacing a filter.
  • Engaging and/or dis-engaging the filtering mechanism may comprise opening and/or closing one or more valves.
  • Engaging and/or dis-engaging the filtering mechanism may be performed manually and/or automated (e.g., controlled).
  • Engaging and/or dis-engaging the plurality of filtering mechanisms e.g., plurality of canisters and/or filters
  • Operations (iv) and (vii) may be performed sequentially or in parallel.
  • FIGs. 19A - 19B show examples of alternating filtering operation between a first filtering mechanism and a second filtering mechanism.
  • Fig. 19A shows an example of connecting a first filtering mechanism (e.g., 1905) to the processing chamber (e.g., 1950) and the pump (e.g., 1955). Connecting may comprise engaging the first filtering mechanism to the processing chamber and/or the pump via one or more valves. Connecting the first filtering mechanism may comprise dis-engaging the second filtering mechanism (e.g., 1910) from the processing chamber and/or pump, via one or more valves. Engaging may comprise opening (denoted by a circle comprising an “X” in Fig.
  • one or more gas flow valves e.g., 1925, 1915. Opening of valves may allow gas (e.g., unfiltered gas, and/or gas comprising gas-borne material) to flow from the processing chamber into the first filtering mechanism. Dis-engaging may comprise closing (denoted by a black circle in the Fig. 19A) one or more valves (e.g., 1920, 1930). The closed valves may isolate the second filtering mechanism from the gas flow mechanism. At times, the first filtering mechanism and/or the second filtering mechanism may be purged.
  • gas e.g., unfiltered gas, and/or gas comprising gas-borne material
  • Dis-engaging may comprise closing (denoted by a black circle in the Fig. 19A) one or more valves (e.g., 1920, 1930). The closed valves may isolate the second filtering mechanism from the gas flow mechanism. At times, the first filtering mechanism and/or the second filtering mechanism may be purged.
  • Purging may include inserting a gas into the first filtering mechanism (e.g., into the filter canister) through at least one valve (e.g., 1942) and/or into the second filtering mechanism through at least one valve (e.g., 1944). Purging may include discharging a gas from the first filtering mechanism through at least one valve (e.g., 1946) and/or from the second filtering mechanism through at least one valve (e.g., 1948). Purging the first filtering mechanism may be done before engaging the first filtering mechanism with the gas flow mechanism (e.g., comprising the processing chamber and/or ancillary chamber). Purging the second filtering mechanism may be done after dis-engaging the second filtering mechanism with the gas flow mechanism.
  • a gas e.g., into the filter canister
  • at least one valve e.g., 1942
  • Purging may include discharging a gas from the first filtering mechanism through at least one valve (e.g., 1946) and/or from the second filtering mechanism through at least one
  • purging the first filtering mechanism and the second filtering mechanism may be done simultaneously. In some examples, purging the first filtering mechanism and the second filtering mechanism may be done sequentially. In some examples, the second filtering mechanism may be purged (e.g., simultaneously) when the first filtering mechanism in engaged and/or in operation as part of the gas flow mechanism.
  • the gas e.g., filtered gas from the first filtering mechanism
  • the gas may be circulated in the processing chamber and/or ancillary chamber (e.g., 1927).
  • the gas e.g., unfiltered gas and/or gas comprising gas-borne material from the processing chamber
  • the first filtering mechanism may be connected to the pump (e.g., 1955).
  • the pump may be disposed adjacent to the ancillary chamber, for example, below or above the ancillary chamber.
  • the pump may induce a flow of gas into the processing chamber and/or the first filtering mechanism.
  • one or more sensors e.g., 1935, 1940
  • a clogging sensor may monitor the amount of gas-borne material collected by the first filter.
  • At least one reactive agent sensor e.g., oxygen sensor and/or humidity sensor
  • the filtering may be switched to a second filtering mechanism on detection (e.g., on detection of a filter full condition, and/or on reaching a pre-determined level of reactive agent(s)) of in-operable condition of the first filtering mechanism.
  • the in-operable conditions may be pre-determined.
  • Fig. 19B shows an example of switching filtering mechanism for filtering the gas, and may follow Fig. 19A in operating sequence respectively.
  • the switching may be performed (i) when at least a portion of the first filter within the first filtering mechanism (e.g., 1960) may be clogged or may be determined as unsafe to use (e.g., according to a sensor, 1990), (ii) when the second filtering mechanism (e.g., 1965) may be present and determined as safe to use (e.g., according to a sensor, 1995), (iii) after a predetermined amount of time, and/or (iv) after a predetermined amount of gas flowing through the filtering mechanism.
  • Switching may comprise purging the second filtering mechanism, e.g., before engaging it with at least one component of the gas flow mechanism.
  • Switching may comprise engaging the second filtering mechanism with at least one component of the gas flow mechanism (e.g., processing chamber).
  • Engaging may comprise opening (denoted by a circle comprising “X” in Fig. 19B) one or more valves (e.g., 1975, 1985).
  • Switching may comprise dis-engaging the first filtering mechanism.
  • Dis-engaging may comprise closing (denoted by a black circle in Fig. 19B) one or more valves (e.g., 1970, 1980).
  • the engaging of first filtering mechanism and dis-engaging of second filtering mechanism may be done simultaneously (e.g., in parallel) or sequentially.
  • the engaging of the second filtering mechanism facilitates a non-interrupted filtering of gas within the gas flow mechanism (e.g., through the processing chamber and/or the ancillary chamber), e.g., during the 3D printing. At least one component of the second filtering mechanism (e.g., the filter) may be monitored.
  • the engaging and/or dis-engaging of first filtering mechanism and the second filtering mechanism may be performed alternatingly to facilitate the non-interrupted filtering of gas that flow out of (e.g., expelled from) the processing chamber (e.g., during the 3D printing).
  • the dis-engaged first filtering mechanism may be removed, replaced, cleaned, refurbished, and/or exchanged.
  • the dis-engaged first filtering mechanism may be purged (e.g., using a nonreactive, and/or inert gas).
  • Purging the first filtering mechanism may comprise inserting a (non-reactive) gas into the first filtering mechanism through at least one valve (e.g., 1962).
  • the inserted gas should not react with the gas-borne material to exceed combustion and/or ignition (e.g., below combustible and/or ignition standards in the jurisdiction).
  • the gas borne material may be collected onto the filter in the filtering mechanism.
  • Purging the first filtering mechanism may comprise discharging a (non-reactive) gas from the first filtering mechanism through at least one valve (e.g., 1972).
  • the non-reactive gas may be a Nobel gas.
  • the filtering mechanisms are configured to provide filtered gas to an optical window purging system (e.g., 1901 and 1981), examples of which are described herein.
  • the filtering mechanisms include fine filters (e.g., 1902, 1903, 1982 and 1983).
  • the fine filters may comprise HEPA filters.
  • the filtering mechanism is operatively coupled to a pump.
  • the pump may facilitate flow of gas (e.g., filtered gas) into the processing chamber and/or through the gas flow mechanism.
  • the pump may facilitate recycling of gas (e.g., filtered gas) into the processing chamber and/or through the filter mechanism(s).
  • the pump may control a property of gas flow (e.g., rate of flow, velocity of gas, and/or pressure of gas). At times, the pump may control a property of the gas-borne material (e.g., velocity, acceleration thereof in at least one component of the gas flow mechanism).
  • the pump may be located adjacent to the filtering mechanism, ancillary chamber, and/or the processing chamber. The pump may be located below, above, and/or adjacent to a side of the ancillary chamber.
  • the pump may be located below, above, and/or adjacent to a side of the processing chamber.
  • the pump may facilitate maintaining a gas pressure within at least a portion of a gas flow mechanism of the 3D printer.
  • the gas flow mechanism may comprise the processing chamber, the ancillary chamber, the build module, the first filtering mechanism, and/or the second filtering mechanism.
  • the gas pressure may be controlled (e.g., to limit an ingress of atmosphere into at least one component of the gas flow mechanism).
  • Controlling may comprise limiting occurrence of a negative pressure with respect to the ambient pressure, in at least one section of the gas flow mechanism.
  • controlling may comprise preventing formation of a negative pressure (with respect to the ambient pressure) in at least one section of the gas flow mechanism.
  • controlling may comprise preventing formation of a negative pressure (with respect to the ambient pressure) in the gas flow mechanism.
  • the at least one section of the gas flow mechanism may comprise an area enclosing the pump (e.g., behind the pump relative to a direction of the gas flow).
  • Controlling may comprise raising pressure (e.g., the pressure of the recirculating gas in the gas flow mechanism) within the gas recirculation system. The pressure may be raised such that there may be (e.g., substantially) no negative pressure within the gas flow mechanism, with respect to the ambient pressure.
  • the pressure in the area enclosing the pump may be at a positive pressure with respect to the ambient pressure, and the pressure within the gas recirculation system may be above the pressure in the area enclosing the pump (e.g., the area just behind the pump).
  • the gas flow pressure within the processing chamber and the pressure directly adjacent to the pump may be different.
  • the raised pressure may be at least about 1 psi, 2 psi, 3 psi, 4 psi, 5 psi, 6 psi, 7 psi, 8 psi, 9 psi, or 10 psi above the ambient pressure.
  • the raised pressure may be any value between the aforementioned values, for example, from about 1 psi to about 10 psi, or from about 1 psi to about 5 psi.
  • the raised pressure may be the pressure directly adjacent to the pump (e.g., behind the pump).
  • the raised pressure may be the average pressure in the gas flow mechanism.
  • a flow of a reactive agent e.g., a reactive gas, such as an oxidizing gas
  • the violent reaction may comprise combustion, ignition, flaring, fuming, burning, bursting, explosion, eruption, or flaming.
  • the violent reaction may be exothermic.
  • the violent reaction may be difficult to contain and/or control once it initiates.
  • the violent reaction may be thermogenic.
  • the violent reaction may exert heat.
  • the violent reaction may comprise oxidation.
  • the 3D printing system may comprise purging.
  • Purging may (e.g., substantially) reduce the likelihood (e.g., prevent) that the gas-borne material violently reacts (e.g., during the 3D printing).
  • Purging may comprise evacuation of a gas (e.g., comprising the reactive agent) from one or more segments (e.g., a processing chamber, an ancillary chamber, a build module, and/or a filtering mechanism) of the 3D printing system.
  • Purging may comprise evacuation of a gas (e.g., comprising a reactive agent) from one or more segments of the gas flow mechanism.
  • a segment may include a compartment (e.g., processing chamber, ancillary chamber, a build module, and/or a filtering mechanism) and/or a channel (e.g., a gas conveying channel, and/or a pre-transformed material conveying channel).
  • Purging may be performed on an individual (e.g., isolatable) segment of the 3D printing system.
  • the isolatable segments may be physically isolated from the gas flow mechanism.
  • the isolatable segments may be fluidly isolated from the gas flow mechanism (e.g., by shutting one or more valves). Purging may be performed on selectable segments of the 3D printing system.
  • Purging may be performed on all segments of the 3D printing system. Purging may be performed individually and/or collectively. Purging of at least two segments may be performed in parallel. Purging of at least two segments may be performed sequentially. Purging may comprise exchanging large quantities of gas in a short amount of time.
  • the reactive agent e.g., oxygen
  • flows into the gas flow mechanism at a maximal rate e.g., during the 3D printing.
  • the reactive agent may flow into the gas flow mechanism at a rate of at most about 5 * 10 2 liters per minute (L/min), 10 2 L/min, 5 * 10 3 L/min, 10 3 L/min, 5 * 10 4 L/min, 5 * 10 4 L/min, 5 * 10 5 L/min, 10 5 L/min, or 5 * 10 6 L/min.
  • the reactive agent may flow into the gas flow mechanism any rate between the aforementioned rates (e.g., from about 5 * 10 2 L/min to about 5 * 10 6 L/min, or from about 10 3 L/min to about 10 5 L/min).
  • the likelihood of the violent reaction is a combination of the velocity of gas, gas temperature, gas pressure, concentration of the reactive agent, concentration of the gas-borne material, or any combination thereof.
  • the purging may comprise slow gas flow (e.g., excluding use of a pump).
  • purging may comprise faster gas flow (e.g., using a pump that facilitates the faster flow of the gas).
  • the slow gas flow may reduce the likelihood (e.g., prevent) a violent reaction of the reactive agent with the gas-borne material (when the reactive agent and/or gas-borne material concentration is height).
  • faster gas flow velocity may be (e.g., substantially) safe to use as the chance of a violent reaction of the reactive agent with the gas-borne material is lowered.
  • Purging can be performed (i) without engaging the pump, (ii) while engaging the pump, (iii) or any combination thereof.
  • purging is initiated after the maintenance mode is engaged, for example, when the level of the reactive agent and/or gas-borne material exceeds a minimum level (e.g., that increases the chance for the violent reaction).
  • the gas flow mechanism may switch between the purging mode(s) and maintenance mode, depending on the level of the gas-borne material and/or reactive agent.
  • purging includes (i) operating a pump in a purging mode, termed herein as a “pump purge mode”, (ii) without operation of a pump, termed herein as a “no pump purge mode”, and/or (iii) maintaining a predetermined pressure value, reactive agent concentration, and/or gas-borne material concentration in the gas flow mechanism, termed herein as a “maintenance mode.”
  • Purging may be performed in the one or more segments of the gas flow mechanism (independently and/or collectively) in the pump purge mode and/or the no-pump purge mode. Purging may be performed independently in at least two segments of the gas flow mechanism in the pump purge mode and/or the no-pump purge mode.
  • Purging may be performed collectively in at least two segments of the gas flow mechanism in the pump purge mode and/or the no-pump purge mode.
  • the pump purge mode may include purging of one or more selectable segments of the gas flow mechanism that are operatively (e.g., fluidly) coupled to the pump.
  • a designated pump is operatively coupled to a segment of the gas flow mechanism.
  • a first designated pump may be operatively coupled to a first segment of the gas flow mechanism
  • a second designated pump may be operatively coupled to a second segment of the gas flow mechanism.
  • the 3D printing system may comprise a (e.g., pressure) maintenance mode.
  • the maintenance may include maintaining a (e.g., pre-determined) pressure level within one or more segments of the gas flow mechanism.
  • the pressure maintenance mode may comprise light purging.
  • the stream of gas evacuated in the light purging comprises a lower rate of gas evacuation as compares to the pump/no-pump purging modes.
  • the gas evacuation in the light purging comprises expelling the gas from the gas flow mechanism through a valve having a small opening (e.g., an opening having a small cross section), as compared to the valves used in the pump/no-pump purge modes.
  • the (e.g., inert) gas entrance in the light purging comprises flowing-in the (e.g., inert) gas from (e.g., from an external source) through a valve having a small opening (e.g., an opening having a small cross section), as compared to the valves used in the pump/no-pump purge modes.
  • the light purging comprises fine tuning of the gas pressure and/or content in at least one section of the gas flow mechanism.
  • the maintenance mode excludes purging.
  • the pressure maintenance mode may comprise lowering (e.g., by evacuating) a concentration of a reactive agent and/or gas-borne material from the one or more segments of the gas flow mechanism.
  • Atmospheric exchange e.g., evacuation of contaminated gas, and entrance of the requested (e.g., inert) gas
  • the atmospheric exchange may be performed at one or more intervals of time.
  • the atmospheric exchange may be performed for a predetermined amount of time.
  • the atmospheric exchange may be performed until a predetermined amount of reactive agent is evacuated from the one or more segments of the gas flow mechanism (e.g., as measured by rate of gas evacuation).
  • the atmospheric exchange may refer to entrance of requested (e.g., inert) gas and evacuation of the reactive agent, from at least a segment of the gas flow mechanism.
  • the purging modes may be switched before, after, and/or during 3D printing.
  • the purging modes may comprise (i) pump purge mode, (ii) no-pump purge mode, and/or (iii) pressure maintenance mode.
  • Switching may comprise switching from a first mode to a second mode (e.g., comprising switching the position of one or more valves and/or the operation status of the pump). Switching may depend on a first threshold value and/or a second threshold value of a level of the reactive agent (e.g., oxidizing gas level). For examples, switching from a first mode to a second mode may depend on the first threshold value of the reactive agent in at least a section of the gas flow mechanism. Switching from the second mode to the first mode may depend on the second threshold value of the reactive agent in at least a section of the gas flow mechanism.
  • the first threshold value and the second threshold value may be (e.g., substantially) the same value. In some examples, the first threshold value and the second threshold value may be different (e.g., forming a hysteresis). The first threshold value may be lower than the second threshold value. The second threshold value may be lower than the first threshold value. Switching may be done manually and/or automatically. For example, switching between the modes may be controlled (e.g., using a controller, and/or processing element).
  • Switching may comprise (i) monitoring a level of the reactive agent, gas-borne material, gas flow velocity, pressure, and/or temperature within one or more segments of the 3D printing system, (ii) comparing the level with a predetermined first threshold value and/or second threshold value of the level, and (iii) switching from a first mode to a second mode, based on the comparison result.
  • switching may comprise (i) monitoring a level of the reactive agent, within one or more segments of the 3D printing system, (ii) comparing the reactive agent level with a predetermined first threshold value and/or second threshold value, and (iii) switching from a first mode to a second mode, based on the comparison result.
  • the first threshold value and/or second threshold value may include a range of values from the first threshold value to the second threshold value.
  • the first threshold value and/or second threshold value may be at least about 1 parts per million (e.g., ppm), 10 ppm, 20 ppm, 30 ppm, 40 ppm, 50 ppm, 60 ppm, 70 ppm, 80 ppm, 90 ppm,
  • the first threshold value and/or second threshold value may be at most about 10 ppm, 20 ppm, 30 ppm, 40 ppm, 50 ppm, 60 ppm,
  • the first threshold value and/or second threshold value may be a range between any of the afore-mentioned values, for example, from about 1 ppm to about 10,000 ppm, from about 3000 ppm to about 5000 ppm, from about 300 ppm to about 500 ppm, from about 1 ppm to about 300 ppm, from about 1ppm to about 500ppm, from about 10ppm to about 200ppm, from about 500 ppm to about 3000 ppm, or from about 5000 ppm to about 10000 ppm.
  • the first reactive agent threshold value for switching from a no-pump purge mode to a pump purge mode is higher than the second reactive agent threshold value for switching from a pump purge mode to a maintenance mode.
  • Higher may be by 0.25, 0.5, 1 , 1 .25, 1 .5, 1 .75, 2, 2.25, 2.5, 2.75, 3, 3.25, 3.5, 3.75, or 4 orders of magnitude.
  • the no-pump purge mode and/or pump purge mode comprises performing independent purging.
  • Independent purging may include performing purging on one or more independent (e.g., isolatable) segments (e.g., a processing chamber, and/or a filtering mechanism) of the 3D printing system.
  • a segment may be operatively coupled to a pump (e.g., in the pump purge mode).
  • a segment may not be coupled to a pump (e.g., in the no-pump purge mode).
  • the no-pump purge mode may be facilitated by the velocity of the requested gas that is inserted (e.g., flushed) into the at least one segment.
  • the inserted gas causes the contaminated gas (e.g., comprising the reactive agent) to expel from the at least one segment (e.g., through a valve, e.g., a vent valve).
  • a valve e.g., a vent valve.
  • One or more isolated segments of the 3D printing system may be purged in parallel to (e.g., simultaneously with) each other.
  • One or more isolated segments of the 3D printing system may be purged sequentially (e.g., first segment may be purged after a second segment in sequence).
  • One or more (e.g., isolated) segments of the 3D printing system may be purged individually (e.g., neither simultaneously, nor in a sequence), simultaneously, sequentially, or any combination thereof.
  • Purging a segment may comprise controlling (e.g., reducing, lowering, and/or maintaining) a level of a reactive agent, gas velocity, temperature, pressure, and/or gas-borne material, such that the reactive agent level may be within a pre-determined (e.g., configurable) threshold value, within the segment.
  • purging a segment may comprise controlling (e.g., reducing, lowering, and/or maintaining) a level of a reactive agent (e.g., oxidizing gas) such that the reactive agent level may be within a pre-determined (e.g., configurable) threshold value, within the segment.
  • the pre-determined threshold value may comply with at least one safety standard in the jurisdiction (e.g., NFPA).
  • the pre-determined threshold value may be within a safe value for gas circulation (e.g., at a velocity, temperature, and/or pressure), for example, as specified in one or more safety standards in the jurisdiction.
  • Purging may comprise insertion of a low reactive gas (e.g., inert gas, e.g., argon) into at least a portion of the segment.
  • Purging may comprise discharging a gas (e.g., comprising a reactive gas agent, for example, an oxidizing gas) from at least a portion of the segment. Insertion and/or discharge of gas may comprise using one or more valves in the segment.
  • Purging may comprise having at least one incoming (e.g., requested) gas through an opened inlet valve and at least one outgoing gas through an opened outlet valve.
  • the requested gas may be from an external source, e.g., a gas cylinder.
  • a gas purge inlet valve may be opened to facilitate insertion of the requested gas into the segment.
  • a gas purge outlet (e.g., vent) valve may be opened to facilitate discharge of (e.g., contaminated) gas from the segment.
  • the gas purge inlet valve and/or gas purge outlet (e.g., vent) valve may be operated manually and/or automatically (e.g., controlled).
  • the gas purge inlet valve and/or gas purge outlet valve may be any valve described herein.
  • the one or more valves may be operatively (e.g., fluidly) coupled to the segment.
  • One or more valves may be closed to facilitate independent and/or isolated purging of at least one segment.
  • one or more valves of the non-selected segments e.g., the segment that is not selected for purging
  • one or more valves of a second filtering mechanism and/or processing chamber may be closed.
  • Purging may include controlling (e.g., monitoring, sensing) a reactive agent level, gas temperature, gas pressure, and/or gas velocity within the isolated segment.
  • Purging may include insertion and/or discharge of gas until the reactive agent level within the segment reaches a pre-determined threshold value.
  • independent purging may be performed until an oxidizing gas level reaches a first threshold value (e.g., 3000 ppm).
  • the first threshold value may be configurable before, during, and/or after 3D printing.
  • Independent purging may be done before, and/or after 3D printing, for example, after a 3D printing of at least one 3D object, between 3D printing cycles of 3D objects, and/or between a pre-transformed material layer dispensing when building a 3D object.
  • Independent purging may be done during the 3D printing, for example, the independent purging mode may be entered into from a collective purging mode, when the gas level within one or more segments in the collective purge mode rises above the predetermined threshold value for the one or more segments.
  • the pump may not be in operation during the independent purging mode (e.g., purging of independent/isolated segments).
  • the pump may not be in operation to (e.g., substantially) prevent violent reaction (e.g., ignition) of reactive (e.g., inflammable) gas-borne material within one or more independent/isolated segments of the 3D printing system.
  • the no-pump purge mode and/or pump purge mode comprises performing collective purging.
  • Collective purging may include purging a plurality of segments (e.g., two, three, four, and/or five) within the 3D printing system together.
  • the plurality of segments may be operatively (e.g., fluidly) coupled to the pump.
  • a first segment may be operatively coupled to a second segment (e.g., through the pump, valve, and/or a channel).
  • Collective purging may include opening one or more valves for (fluidly) connecting one or more segments (e.g., opening one or more valves for the processing chamber and one or more valves for the filtering mechanism) to the pump.
  • Opening of one or more valves may be done (e.g., controlled) manually and/or automatically.
  • Collective purging may include selecting one or more segments for purging. For example, a first filtering mechanism and a second filtering mechanism may be selected for collective purging, and a processing chamber may not be selected for purging. For example, the first filtering mechanism and the processing chamber may be selected for collective purging, and the second filtering mechanism may not be selected for purging.
  • the pump e.g., a blower
  • the pump is coupled to the purged sections and is in operation when performing collective purging.
  • the pump e.g., a blower
  • the pump is not coupled to the purged sections and/or is not in operation when performing collective purging.
  • the engagement of the pump may depend on the temperature, pressure, velocity, gas-borne material concentration, and/or reactive species concentration, of the gas in the segments.
  • the purging and/or maintenance may be done before the 3D printing (e.g., to ready the 3D printer for 3D printing).
  • the pump may induce a gas circulation within a gas circulation loop of the gas flow mechanism.
  • a gas recirculation loop may comprise conveyance (e.g., flow) of a gas (e.g., filtered and/or clean) gas into at least a portion of the processing chamber.
  • the gas circulation loop may comprise conveyance of gas from the filtering and/or recycling mechanism into at least a portion of the processing chamber.
  • the gas recirculation loop may comprise conveyance of gas (e.g., unfiltered gas including gas borne material) from the processing chamber into the filtering and/or recycling mechanism.
  • the conveyance of the gas may be induced by the pump and/or by influx of a requested (e.g., inert) gas into the gas flow mechanism.
  • purging may comprise maintaining a pressure level of reactive agent (e.g., an oxidizing gas), and/or gas-borne material.
  • Pressure may be maintained at a pre-determined (e.g., configurable) level and/or within a pre-determined (e.g., configurable) range.
  • Pressure maintenance may comprise maintaining the same pressure in one or more selected segments (e.g., within an error value of at most 20%, 10%, 5%, or 1%).
  • Pressure maintenance may comprise maintaining the same pressure in all segments that may be operatively coupled to the pump (e.g., within an error value of at most 20%, 10%, 5%, or 1%).
  • Pressure maintenance may comprise maintaining different pressure (e.g., within an error value of at most 20%, 10%, 5%, or 1%) within different segments. Pressure maintenance may be performed during 3D printing (e.g., when transforming the pre-transformed material, and/or irradiating with an energy beam). Pressure maintenance may comprise controlling reactive agent level within one or more segments during at least a portion of 3D printing (e.g., during operation of the energy beam). Pressure maintenance may comprise controlling one or more valves (e.g., a modulating valve). A modulating valve may be operatively coupled to a segment of the 3D printing system. Pressure maintenance may include facilitating a finer control of gas flow into the segment (e.g., during maintenance mode).
  • the modulating valve may facilitate control of conveyance (e.g., insertion, amount, and/or flow rate) of gas into at least a segment of the gas flow mechanism.
  • the modulation valve may have a smaller cross section (e.g., diameter) than a purge valve (e.g., gas purge inlet valve and/or a gas purge outlet valve).
  • the inlet modulation valve may facilitate slow mass flow of gas into the gas flow mechanism as compared to a mass flow through a gas purge inlet valve.
  • the outlet modulation valve may facilitate slow mass flow of gas from the gas flow mechanism as compared to a mass flow through a gas purge outlet valve.
  • the modulation valve may facilitate pressure maintenance within at least a portion of a segment of the 3D printing system, that may be operatively coupled to the pump.
  • Pressure maintenance may include controlling the pressure in real-time. Real time may be during at least a portion of 3D printing (e.g., during irradiation, planarization of an exposed surface of the material bed, dispensing pre-transformed material, recycling, filter exchange, and/or pre-transformed material conveyance).
  • gas may be circulated until occurrence of a predetermined threshold value of a physical property (e.g., time, and/or temperature), or a signal (e.g., end of a 3D printing cycle).
  • purging may comprise maintaining a reactive agent level (e.g., an oxidizing gas level) at a pre-determined level and/or between a pre-determined range (e.g., between a first threshold value and a second threshold value, e.g., that form a hysteresis).
  • the pre-determined level and/or range may be for a plurality of segments (e.g., two, three, and/or all) within the gas flow mechanism of the 3D printing system.
  • the predetermined level and/or range may be of an individual (e.g., isolatable) segment of the gas flow mechanism.
  • the pre-determined level and/or range configured for a segment.
  • the operation modes of the gas flow mechanism may be switched based on the pre-determined level and/or range.
  • Fig. 20 shows an example of switching between the modes based on pre-determined threshold levels.
  • the first operation mode e.g., 2005
  • the first mode may comprise no-pump purge mode or independent purging.
  • the second operation mode e.g., 2010
  • the mode may be switched back from the second mode to the first mode when the reactive agent level exceeds a second threshold value.
  • the second mode may comprise collective purging or pump purge mode.
  • the third operation mode (e.g., 2015) may be initiated when the reactive agent level is at or below a third threshold value.
  • the third mode may comprise the maintenance mode.
  • the third operation mode may be entered into from the second operation mode.
  • the third operation mode may be switched back to a second operation mode when the reactive agent level exceeds a fourth threshold value.
  • the second threshold value can be above the first threshold value.
  • the fourth threshold value can be above the third threshold value.
  • the second threshold value can be above: the third threshold value and the fourth threshold value.
  • the first threshold value can be above: the third threshold value and the fourth threshold value.
  • a segment is operatively coupled to one or more valves.
  • the valve may facilitate adequate (e.g., minimal) use of gas within one or more segments of the 3D printing system.
  • the valve may facilitate flow of gas through the valve (e.g., Fig. 14,
  • the valve may facilitate insertion of a (e.g., requested) gas into a segment of the gas flow mechanism (e.g., a gas purge inlet valve, Fig. 14, 1455, 1465, and/or 1430,).
  • the valve may facilitate discharge of a (e.g., contaminated) gas from the segment (e.g., a gas purge vent valve, Fig. 14, 1475, and/or 1435).
  • the valve may facilitate controlling a physical property (e.g., atmosphere, pressure, temperature and/or reactive agent level) within the segment, for example, using a modulating valve (e.g., outlet modulating valve 1445, and/or inlet modulating valve 1425).
  • a modulating valve e.g., outlet modulating valve 1445, and/or inlet modulating valve 1425.
  • At least two valves in the gas flow mechanism may have a different cross-section. At least two valves in the gas flow mechanism may have the same cross section.
  • the valves may be manually and/or automatically controlled.
  • the valves may be controlled based on a signal from one or more sensors and/or controller.
  • Valves may be controlled (e.g., opened, closed and/or adjusted) before, during, and/or after the 3D printing.
  • one or more segments of the gas flow mechanism may be operatively (e.g., physically and/or fluidly) coupled to the processing chamber.
  • the coupling may be direct and/or indirect.
  • the coupling may be through a channel (e.g., through a gas conveying and/or a material conveying channel).
  • Examples of indirect coupling include through an atmosphere in the segment.
  • an atmosphere of the processing chamber may be coupled to an opening in at least one component of a layer dispensing mechanism (e.g., recoater), the layer dispensing mechanism may be in turn coupled to a pre-transformed material conveyance system, e.g., that comprises a bulk reservoir.
  • a layer dispensing mechanism e.g., recoater
  • the pretransformed material conveyance system may be any pre-transformed material conveyance system such as, for example, the one described in Provisional Patent Application serial number 62/471 ,222 filed March 14, 2017, titled OPERATION OF THREE-DIMENSIONAL PRINTER COMPONENTS,” which is entirely incorporated herein by reference.
  • a material removal mechanism opening may be opened into the processing chamber atmosphere.
  • a material dispenser exit opening may be opened to the processing chamber atmosphere and thus fluidly connect the material conveyance mechanism to the gas flow mechanism.
  • the one or more segments may include a segment that comprises a gas-borne material.
  • a reactive agent e.g., reactive species such as an oxidizing gas
  • the at least one segment of the gas flow mechanism e.g., filtering mechanism
  • the flow of gas-borne material within one or more segments of the 3D printing system may violently react with the reactive agent.
  • purging may be performed within the one or more segments of the gas flow mechanism.
  • material is ejected to the atmosphere of the processing chamber and/or processing cone during at least a portion of the 3D printing. At least a portion of the ejected material may be included in the gas-borne material. At least some of the ejected material may be returned to the material bed. For example, at least about 1%, 5%, 10%, 20%, 30%, 50%, or 80% of the ejected material may be returned to the material bed (e.g., after being recycled, e.g., reconditioned and/or separated).
  • the ejected material may be returned to the material bed (e.g., after being recycled, e.g., reconditioned and/or separated).
  • the ejected material that is returned to the material bed may be between any of the aforementioned values (e.g., from about 1% to about 90%, from about 5% to about 80%, or from about 5% to about 30%).
  • all the volume of the processing cone (e.g., Fig. 15, 1530), is exchanged during a 3D printing cycle at least once.
  • the volume may comprise the atmosphere.
  • all the volume of the processing chamber (e.g., Fig. 8, 826), is exchanged during a 3D printing cycle at least once.
  • Substantially all the volume may be at least about 70%, 80%, 90%, 95%, 95%, or 99% of the total volume (percentages are volume per volume).
  • Substantially all the volume may be any value between the afore-mentioned values (e.g., from about 70% to about 99%, from about 80% to about 99%, or from about 90% to about 99%).
  • the volume exchanged during a 3D printing cycle may be exchanged at least 1 time (“ * ”), 2 * , 3 * , 4 * , 5 * , 6 * , 7 * , 8 * , 9 * , or 10 * .
  • the volume (e.g., atmosphere) may be exchanged any number of times between the afore mentioned number of times (e.g., from 1 * to 10 * , from 1 * to 5 * , or from 1 * to 3 * ).
  • the gas flows at a speed in the processing cone and/or processing chamber.
  • the gas flow may be from one end of the processing chamber to its opposing end.
  • the gas flow may be from one end of the processing cone to its opposing end.
  • the gas may flow laterally. At least a portion of the gas flow may be horizontal. At least a portion of the gas flow may be laminar.
  • the (e.g., average or mean) speed of the gas flow may be at least about 10 millimeters per second (mm/sec), 20 mm/sec, 50 mm/sec, 80 mm/sec, 100 mm/sec, 200 mm/sec, 400 mm/sec, or 500 mm/sec.
  • the (e.g., average or mean) speed of the gas flow may be at most about 20 mm/sec, 50 mm/sec, 80 mm/sec, 100 mm/sec, 200 mm/sec, 4000 mm/sec, or 600 mm/sec.
  • the (e.g., average or mean) speed of the gas flow may be at any value between the afore-mentioned values (e.g., from about 10 mm/sec to about 600 mm/sec, from about 10 mm/sec to about 300 mm/sec, or from about 50 mm/sec to about 200 mm/sec).
  • the atmosphere e.g., comprising a gas
  • Exchanged may comprise changing the position of one or more atmospheric components (e.g., gas and/or debris).
  • the time it takes for an atmospheric component to leave the processing cone and/or chamber is at most about 1 second, 2sec, 5sec, 8sec, 10sec, 15sec, 20sec, 30sec, 50sec, 1min, 5min, 10min, or 30min.
  • the time it takes for an atmospheric component to leave the processing cone and/or chamber is of any time values between the afore-mentioned values (e.g., from about 1sec to about 30min, from about 1sec to about 30sec, from about 1sec to about 15sec, or from about 5sec to about 1 min).
  • the gaseous atmosphere is flowing during at least a portion of the 3D printing.
  • the gaseous atmosphere may flow at a rate of at least about 10 cubic feet per minute (CFM), 20CFM, 30CFM,
  • the gaseous atmosphere may flow at a rate between any of the afore-mentioned rates (e.g., from about 10 CFM to about 3000CFM, from about 10CFM to about 1000CFM, or from about 100CFM to about 500CFM).
  • the gaseous atmosphere may be translated by a pump (e.g., a blower).
  • the processing cone and/or processing chamber is devoid of standing vortices, and/or turbulence that are larger than a threshold value.
  • the processing cone and/or processing chamber may be devoid of standing vortices, and/or turbulence that have a FLS of at least about 0.25 millimeter (mm), 0.5mm, 1 mm, 2mm, 5mm, 10mm, 15mm, 20mm, or 50mm.
  • the processing cone may be devoid of standing vortices, and/or turbulence that have a FLS greater than any value between the afore-mentioned values (e.g., from about 0.25 mm to about 50mm, from about 0.5mm to about 20mm, or from about 1 mm to about 20mm).
  • the processing chamber and/or processing cone may be (e.g., substantially) devoid of standing vortices and/or turbulence.
  • the standing vortex may be horizontal, angular, and/or angled.
  • a non-gaseous material is disposed in the atmosphere.
  • the material may be debris (e.g., soot), or pre-transformed material (e.g., powder).
  • the material may be dispersed in the atmosphere of the processing chamber and/or cone.
  • the debris may be ejected to the atmosphere of the processing chamber and/or cone during at least a portion of the 3D printing.
  • most of the material that is ejected during the 3D printing is evacuated by the gas flow. Most of the evacuated material may be at least about 70%, 80%, 90%, 95%, 98%, or 99% of the total material (percentages are volume per volume). Substantially all the material may be any value between the afore-mentioned values (e.g., from about 70% to about 99%, from about 80% to about 99%, or from about 90% to about 99%).
  • pre-transformed material is transformed (e.g., using an energy beam).
  • the transformed material may transfer to the atmosphere of the processing cone and/or processing chamber (e.g., as debris and/or plasma).
  • at times, at least a portion of the material that transfers to the atmosphere may have a (e.g., average or mean) FLS of at most about 20micrometers (pm), 15pm, 10pm, 8pm, 5pm, 4pm, 3pm, 2pm, 1 pm, or 0.5pm.
  • At least a portion of the material that transfers to the atmosphere may have a (e.g., average or mean) FLS of any value between the aforementioned values (e.g., from about 15pm to about 15pm, from about 15pm to about 15pm, from about 15pm to about 15pm, from about 15pm to about 15pm).
  • the portion of the material that transfers to the atmosphere having the above-mentioned (e.g., average or mean) FLS may be at least about 70%, 80%, 90%, or 95% of the total material that transfers to the atmosphere (e.g., debris ejected by the vaporization of the transformed material, e.g., using the energy beam).
  • the portion of the material that transfers to the atmosphere may be carried by the gas flow.
  • the atmosphere of the processing cone and/or chamber comprises debris and/or particulate material.
  • the debris and/or particulate material may be at most 100ppm, 50ppm, 10ppm, 5ppm, 1ppm, 500ppb, 250ppb, 150ppb, 100ppb, or 50ppb of the volume of the processing cone and/or chamber (calculated weight per weight).
  • the debris and/or particulate material may be a portion of the volume of the processing cone and/or chamber (calculated weight per weight) between any of the afore-mentioned values (e.g., from about 100ppm to about 50ppb, from about 10ppm to about 50ppb, from about 5ppm to about 50ppb, or from 1ppm to about 50ppb).
  • particulate material and/or debris is ejected into the atmosphere of the processing chamber and/or processing cone during at least a portion of the 3D printing. In some embodiments, at least a portion of the ejected material (comprising debris and/or particulate material) remains in the processing cone and/or processing chamber for at least about 0.1 second (sec), 0.2 sec, 0.5sec, 1sec, 5sec, 10sec, 30sec, 50sec, or 80sec.
  • the at least a portion of the ejected material remains in the processing cone and/or processing chamber for any time period between the above- mentioned time periods (e.g., from about 0.1 sec to about 80sec, from about 0.5 sec to about 10sec, from about 0.1 sec to about 5 sec, or from about 0.1 sec to about 10sec).
  • the at least a portion of the ejected material that remains in the processing chamber and/or cone may be at most about 0.001%, 0.005%, 0.01%, 0.05%, 0.1%, 0.5%, or 1% of the total ejected material (calculated either volume per volume or weight per weight).
  • the gas flow mechanism comprises one or more sensors (e.g., Fig. 14, 1470, 1480, 1485, 1490, 1495, 1415 and 1416).
  • the sensor may (e.g., continuously) operate during at least a portion of the 3D printing process.
  • the sensor may be controlled (e.g., manually and/or automatically).
  • the sensor may be activated and/or de-activated by a controller.
  • the sensor may be placed between the enclosure and the recycling system.
  • the sensor may be placed within the enclosure.
  • the sensor may be placed between the inlet portion and the processing chamber.
  • the sensor may be placed between the outlet portion and the processing chamber.
  • the sensor may comprise pressure sensors, position sensors, velocity sensors, optical sensors, mass flow sensors, gas flow sensors, motion sensors, thermal sensors, pressure transducers, or any other sensor mentioned herein.
  • the controller is operatively coupled to any system, mechanism, or apparatus disclosed herein (or any of their components).
  • operatively coupled or “operatively connected” refers to a first mechanism that is coupled (or connected) to a second mechanism to allow the intended operation of the second and/or first mechanism.
  • the gas flow mechanism includes a controller (e.g., a variable frequency driver) to control the gas flow rate.
  • the gas flow mechanism may sense the rate of gas flow and/or the rate of mass flow.
  • Gas flow sensors may comprise sensing the volumetric flow of gas.
  • Mass flow sensors may comprise sensing the mass flow of gas.
  • the controller may direct the inlet portion and/or outlet portion to alter the amount of gas flow.
  • the alteration of the gas flow may comprise (i) closing an opening at least in part, (ii) reshaping the opening, (iii) changing a position of a ledge, or (iv) changing a position of a baffle.
  • the magnitude and/or velocity of gas may be controlled.
  • the velocity and/or magnitude of gas that exits the recycling mechanism may be altered.
  • Altered may comprise increasing the gas velocity.
  • Altered may comprise decreasing the gas velocity.
  • Altered may comprise statically setting the velocity of the gas.
  • Altered may comprise dynamically changing the velocity of the gas (e.g., based on a sensed gas value).
  • the dynamic change may comprise a closed loop control.
  • the dynamic change may comprise a feedback loop control.
  • the dynamic change may comprise comparison to a target value.
  • Altered may comprise statically setting the magnitude of gas.
  • Altered may comprise dynamically changing the magnitude of gas.
  • the gas flow mechanism comprises a sensor (e.g., optical sensor) that senses a composition of gas.
  • the sensor may be operatively coupled to a gas filtering mechanism.
  • the sensor may sense impurities (e.g., oxygen, water) within the gas.
  • the sensor may sense reactive species (e.g., oxidizing gas, water) within the gas.
  • the gas may be reconditioned based on the sensed impurities.
  • the gas flow mechanism comprises at least one sensor that senses the amount of debris in the enclosure.
  • the sensor may be an optical sensor.
  • the sensor may be a plasma.
  • the sensor may be a spectroscopic sensor.
  • the sensor may be operatively coupled to the pump and/or to the valve.
  • a controller may control the velocity of at least one gas stream (e.g., within the multiplicity of incoming gas streams to the processing chamber). The control may take into account a signal from the sensor. For example, when the enclosure contains a large amount of debris, the controller may direct a stronger flow of the gas at least into the processing cone (e.g., into the enclosure).
  • the controller may direct a softer flow of the gas at least into the processing cone (e.g., into the enclosure).
  • the at least one sensor may sense a debris in a portion of the enclosure (e.g., in the processing cone).
  • the at least one sensor may comprise a plurality of sensors.
  • a controller may individually control the velocity of at least two of a plurality of gas streams (e.g., within the multiplicity of incoming gas streams to the chamber).
  • a controller may collectively control the velocity of at least two of a plurality of gas streams (e.g., within the multiplicity of incoming gas streams to the chamber). At times, at least two gas streams are controlled by separate controllers (e.g., that makeup a control system).
  • the control may take into account a signal from the sensor which provides information on the concentration, type, and/or location of the debris at least in the processing cone (e.g., in the processing chamber).
  • the processing cone may contain a large amount of debris in a first enclosure atmosphere location and a small amount of debris in a second enclosure atmosphere location
  • the controller may direct a stronger flow of the gas to the first location and a softer stream of gas to the second location.
  • the first and second atmosphere locations may differ in their horizontal and/or vertical position.
  • the controller adjusts the relative flow of the individual gas streams based on a debris in a particular position in at least the atmosphere of the processing chamber (e.g., in the enclosure). For example, when the enclosure contains debris that slows down the flow of a gas stream, the controller may direct an increase of the flow of that gas stream (e.g., to that position), and/or slowing down the gas flow in adjacent gas streams (e.g., to direct the debris towards that adjacent gas streams). For example, when the enclosure contains debris that absorbs and/or deflects the energy beam that is directed towards the material bed (e.g., Fig. 8, 801), the controller may direct an increase of the flow of that gas stream (e.g., to that position), and/or slow down the gas flow in adjacent gas streams (e.g., to direct the debris towards that adjacent gas streams).
  • the controller may direct an increase of the flow of that gas stream (e.g., to that position), and/or slow down the gas flow in adjacent gas streams (e.g., to direct the debris towards that
  • the gas flow mechanism comprises one or more valves and/or gas apertures (e.g., gas opening-ports).
  • the valve and/or a gas aperture may be disposed adjacent to the recycling system.
  • the valve and/or a gas aperture may be disposed adjacent to the pump.
  • the valve and/or a gas aperture may be disposed between the processing chamber and the recycling system.
  • the valve and/or a gas aperture may be disposed adjacent to the inlet portion.
  • the valve and/or a gas aperture may be disposed adjacent to the outlet portion.
  • Fig. 14 shows an example of valves (e.g., 1410, 1420).
  • the gas may travel (e.g., enter and/or exit) through the valve.
  • the valve may control the amount, and/or direction of gas flow through it.
  • the valve may control if a gas does or does not flow through it.
  • the gas may enter or exit the build module, processing chamber, and/or enclosure through the valve.
  • the valves may control (e.g., regulate) the flow of gas to and/or from a compartment.
  • the compartment may comprise the enclosure, pump or the recycling mechanism.
  • the valves may be a pneumatic control valves.
  • the valves may isolate the filter from the enclosure and/or pump. Examples of valves comprise butterfly valve, relief valve, ball valve, needle valve, solenoid valve, leak valve, pressure gauge, or a gas inlet.
  • the valve may comprise any valve disclosed herein.
  • the valve may be controlled manually and/or electronically (e.g., by a controller). The control of the valve may be during at least a portion of the 3D printing.
  • a 3D printing system includes features that cooperate with or compensate for certain flow dynamics of gas within an enclosure.
  • a power density of an energy beam that reaches a target surface can be altered (e.g., reduced) due to being absorbed by and/or reflected from gas-borne debris (e.g., soot) that is generated during a 3D printing.
  • the target surface may comprise an exposed surface of a material bed, or an exposed surface of a 3D object.
  • the gas-borne debris may deposit onto at least one surface within the enclosure (such as surfaces of an optical window) which deposited debris can reduce a power density of the energy beam that reaches the target surface.
  • Providing a gas flow across the target surface may be used to alter (e.g., lessen) a concentration of the debris within at least a portion of the processing chamber during, before, and/or after a 3D printing (e.g., in a controlled manner).
  • the processing chamber and build module are reversibly separable components (e.g., can reversibly and/or controllably engage and disengage) while, in other embodiments, the processing chamber and build module are portions of an inseparable single unit.
  • the processing chamber and the build module can combine to form an enclosure for 3D printing.
  • the 3D printer can comprise a build module that includes a platform.
  • the platform is configured to support and move material bed, which is comprised of pre-transformed material (e.g., metal powder).
  • the energy source can be configured to generate an energy beam, which can be used to transform a pre-transformed material (e.g., of material bed, or a material bed that flows towards the platform) to a transformed material.
  • an optical mechanism is used to control the energy beam (e.g., control the trajectory of energy beam 2108 in processing chamber 2102).
  • Fig. 21 shows an example of a 3D printer 2100 which includes features for controlling gas flow.
  • the 3D printer 2100 includes a processing chamber 2102, build module 2104 and a material bed 2113 disposed above a platform 2112, and a 3D object 2121 disposed in the material bed.
  • the 3D printer 2100 is operatively coupled to an energy source 2106 that generates an energy beam 2108, which energy beam is directed by an optical mechanism 2111 towards the material bed and/or a target surface (e.g., of the 3D of the 3D object 2121), which energy beam travels through an optical window 2103 and an atmosphere of the main internal space 2127 (also referred to herein as the “main internal portion of the processing chamber”) of the processing chamber 2102.
  • Components of Fig. 21 can be disposed relative to gravitational vector 2199 pointing to gravitational center G.
  • the 3D printer comprises gas flow in the processing chamber.
  • the gas flow can be before, after, and/or during the 3D printing.
  • the gas flow can be controlled manually and/or automatically.
  • the automatic control may comprise using one or more controllers, e.g., as described herein.
  • the processing chamber is operatively coupled (e.g., physically connected) or may comprise a gas inlet portion (which may also be referred to herein as “inlet portion”, “entrance portion” or “first portion”).
  • the gas inlet portion is operatively coupled to (e.g., physically connected) or may comprise (e.g., is an integral part of) the processing chamber.
  • the gas inlet portion may be configured to facilitate gas flow therethrough.
  • the gas inlet portion may comprise a gas inlet port (which may also be referred to herein as “inlet port”, “entrance port” , “first inlet port”, “first entrance port”) and/or a gas outlet port (which may also be referred to herein as “outlet port”, “exit port”, “first outlet port” or “first exit port”).
  • the processing chamber may be operatively coupled to the gas inlet portion (e.g., mainly or only) through the gas outlet port of the gas inlet portion.
  • the gas inlet portion may be configured to enclose the gas.
  • the gas inlet portion may comprise a 3D (e.g., geometric) shape.
  • the gas inlet portion may enclose an internal space.
  • the gas inlet portion may be configured to reduce an ambient atmosphere from entering the gas inlet portion (e.g., at least during the 3D printing).
  • the gas inlet portion may comprise a positive pressure (e.g., above an ambient pressure), e.g., before, after and/or during the 3D printing.
  • the pressure within the gas inlet portion may be controlled (e.g., automatically and/or manually) before, after, and/or during the 3D printing.
  • the gas inlet portion may comprise one or more channels and/or baffles.
  • the channels may be formed using the one or more baffles.
  • the one or more baffles may contact (e.g., border) one or more walls of the gas inlet portion.
  • the inlet portion may facilitate a gas flow therethrough.
  • the channels and/or baffles may facilitate altering a behavior of (i) the gas that flows therethrough and/or (i) the gas that is expelled from the gas inlet portion.
  • the (e.g., 3D) shape of the gas inlet portion may facilitate altering the behavior of the (i) gas that flows therethrough and/or (i) the gas that is expelled from the gas inlet portion.
  • the (e.g., 3D) shape of the gas inlet port and/or gas outlet port of the gas inlet portion may facilitate altering the behavior of the (i) the gas that flows therethrough and/or (i) the gas that is expelled from the gas inlet portion.
  • the gas may enter the gas inlet portion through its gas inlet port, and exit the gas inlet portion through its gas outlet port.
  • the gas may enter the processing chamber (e.g., or the main portion of the processing chamber) and flow over (and/or on) a target surface (e.g., an exposed surface of the material bed and/or the 3D object).
  • the gas inlet portion e.g., its 3D shape, channel(s), baffle(s), inlet port(s), and/or outlet port(s)
  • the gas inlet portion (and/or any component thereof) is configured to direct the flow of gas in a first direction (e.g., x direction), and/or alter (e.g., reduce) a flow of gas in a second direction (e.g., y direction).
  • the first direction may be different than the second direction.
  • the first direction may be (e.g., substantially) orthogonal to the first direction (e.g., x direction).
  • Altering the gas flow may comprise altering the velocity, direction, laminarity, turbulence, cross sectional shape, and/or cross-sectional area of the gas flow.
  • the cross section may be in a direction orthogonal to the direction of the gas flow.
  • the gas inlet portion is configured to provide a (e.g., substantially) uniform flow of gas that is directed toward a target surface. In some embodiments, the gas inlet portion is configured to provide a (e.g., substantially) uniform flow of gas that is directed away from a target surface. In some embodiments, the gas inlet portion is configured to provide a (e.g., substantially) uniform flow of gas that is directed tangential or parallel to the target surface. In some embodiments, the gas inlet portion is configured to provide a flow of gas above a target surface.
  • the gas may exit the processing chamber through a gas outlet portion (also referred to herein as the “outlet portion” or “second portion”).
  • the gas outlet portion is operatively coupled (e.g., physically connected) or may comprise (e.g., is an integral of) the processing chamber.
  • the gas outlet portion may be configured to facilitate gas flow therethrough.
  • the gas outlet portion may comprise a gas inlet port (also referred to herein as “inlet port” or “second inlet port”) and/or a gas outlet port (also referred to herein as “outlet port” or “second outlet port”).
  • the gas may enter the gas outlet portion through its gas inlet port, and exit the gas outlet portion through its gas outlet port.
  • the processing chamber may be operatively coupled to the gas outlet portion (e.g., mainly or only) through the gas inlet port of the gas outlet portion.
  • the gas outlet portion may be configured to enclose the gas.
  • the gas outlet portion may comprise a 3D (e.g., geometric) shape.
  • the gas outlet portion may enclose an internal space.
  • the gas outlet portion may be configured to reduce an ambient atmosphere from entering the gas inlet portion (e.g., at least during the printing).
  • the gas outlet portion may comprise a positive pressure (e.g., above an ambient pressure), e.g., before, after and/or during the 3D printing.
  • the pressure within the gas outlet portion may be controlled (e.g., automatically and/or manually) before, after, and/or during the 3D printing.
  • the gas outlet portion may comprise one or more channels and/or baffles.
  • the gas outlet portion is clear of channels and/or baffles.
  • the gas outlet portion may facilitate a gas flow therethrough (e.g., channel gas flow within).
  • the gas outlet portion can have channels, baffles, and/or a 3D shape that can facilitate altering and/or preserving a behavior of the gas that flows therethrough.
  • the gas outlet portion can include features that reduces an occurrence of at least some the gas that enters the gas outlet portion (e.g., exiting the processing chamber or the main portion of the processing chamber) from returning to at least an area occupied by the processing cone, which may otherwise generate standing vortices at least in the region (e.g., volume) occupied by the processing cone or generating turbulence at least in the region occupied by the processing cone (e.g., in the main portion of the processing chamber), or any combination thereof.
  • features of the gas outlet portion are configured to provide a flow of gas that is (e.g., substantially) free of turbulence, standing vortices, and/or back flow.
  • the features of the gas outlet portion are configured to direct the flow of gas towards the outlet port of the gas outlet portion.
  • the gas outlet portion is configured to alter the gas flow as it flows therethrough. Altering the gas flow may comprise altering the velocity, direction, laminarity, turbulence, cross sectional shape, and/or cross-sectional area of the gas flow.
  • the cross section of the gas outlet portion may vary in order to efficiently direct gas out of its outlet port.
  • the gas outlet port may direct some of the flow of gas in a direction orthogonal to a main direction of the gas flow.
  • the gas outlet portion is configured to provide a (e.g., substantially) non-turbulent flow of gas that is directed towards its outlet port and/or away from the processing chamber (e.g., the processing cone).
  • the gas outlet portion may be separated from a main internal portion of the processing chamber by a wall (e.g., comprising an opening).
  • the gas outlet portion can have a tapered shape (aerodynamic shape).
  • An internal surface of the processing chamber can include a curvature (e.g., facilitating an aerodynamic shape).
  • the aerodynamic shape can be configured (e.g., designed) to (i) concentrate the gas flow, (ii) lessen back flow, (iii) lessen generation of turbulence, (iv) lessen generation of standing vortices, or (v) any combination thereof. Reducing the turbulence, standing vortices, and/or back flow is at least within the area confined by the processing cone.
  • Fig. 21 shows an example of a gas flow route, which gas enters through inlet port 2116 of gas inlet portion 2114 (e.g., along the direction of the arrow above numeral 2116), exits the gas inlet portion 2114 through outlet port 2124 into the main internal portion 2127 of the processing chamber 2102, flows over (and/or on) surface 2120 of the material bed 2113 and/or 3D object 2121 in a general direction 2119, enters the gas outlet portion 2117 through an inlet port 2130, and exits the gas outlet portion through outlet port 2118.
  • Fig. 21 shows an example of an internal surface 2128 of the processing chamber.
  • the gas inlet portion e.g.,
  • the gas outlet portion (e.g., 2132), also referred to as a first wall.
  • the gas can be separated from the main internal portion (e.g., 2127) of the processing chamber by a wall (e.g., 2131), also referred to as a second wall.
  • the gas flows through one or more openings (e.g., slit(s)) (e.g., 2140) within the wall.
  • the size of one or more openings is adjustable (e.g., able to be made larger and/or smaller).
  • the adjusting can change a flow of the gas entering the outlet portion.
  • the adjusting can be accomplished using, for example, one or more adjustable valves.
  • the gas outlet portion and main internal portion are not separated by a wall. In the example shown in Fig.
  • the inlet portion comprises baffles 2115 that form a (e.g., winding) channel.
  • the outlet portion is devoid of baffles.
  • the general direction of gas flow shown in the example of Fig. 21 is illustrated by arrows e.g., next to numerals 2116, 2119, and 2126.
EP22756811.0A 2021-02-17 2022-02-16 Gasstrom beim dreidimensionalen drucken Pending EP4294591A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202163150231P 2021-02-17 2021-02-17
PCT/US2022/016550 WO2022177952A1 (en) 2021-02-17 2022-02-16 Gas flow in three-dimensional printing

Publications (1)

Publication Number Publication Date
EP4294591A1 true EP4294591A1 (de) 2023-12-27

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EP22756811.0A Pending EP4294591A1 (de) 2021-02-17 2022-02-16 Gasstrom beim dreidimensionalen drucken

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