Uniform Binder Distribution in 3D Printers

Binder injection molding equipment and method for 3D printing multi-material parts with different properties in different areas. The equipment has a platform with moving axes and multiple nozzles that can spray different binders simultaneously. This allows printing components with multiple material systems in the same part. The binders can have different properties like strength, porosity, and thermal conductivity. By selectively jetting binders in different areas, components with targeted properties can be created.

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A jet binder printing system and method that allows separating powder deposition and fusing steps to overcome limitations of in-situ powder bed printing. The system has modules for adjustable binder, powder dispensing, compaction, primary binder, and fusing. It enables creating stable, transferable, and customizable powder layers on a carrier substrate. The adjustable binder sticks the powder in pattern, then compacted and primed layers are fused separately. This allows optimizing layer properties, avoiding contamination, and rejecting defective layers.

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A method for manufacturing 3D printed objects that reduces chipping and improves surface quality. The method involves applying different amounts of binder in the contour region versus the interior regions of the powder bed. This provides better binding strength in the critical outer layer where chipping is most likely. By applying more binder to the contour area, the outer layer bonds better and reduces the risk of powder removal or chipping during handling and transport.

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A loading system for 3D printers that reduces mounding and increases uniformity of powder layers. The system has a loading chamber positioned over the supply container. Powder is dispensed into the chamber and compacted to increase uniformity. The chamber floor is then lowered into the supply container, transferring the compacted powder. This loading process helps distribute the powder more evenly throughout the container than directly filling it.

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A high-efficiency two-way powder spreading 3D printing method that improves print quality and speed by spreading powder in layers using a reciprocating motion. The method involves laying down two layers of powder horizontally instead of just one. This allows printing on both layers in each pass. The powder spreading device moves back and forth between the layers while a scraper levels the powder. The printing nozzle then follows to deposit binder on both layers. This reduces printing time compared to traditional layer-by-layer methods. The powder spreading device has a dual-capacity powder tank and scrapers on both sides.

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Low viscosity binder for 3D printing that improves green body strength and reduces residual ash compared to existing water-based and organic solvent binders. The binder is a two-component system with one component reinforcing the powder surface and the other component bonding the powder together. The reinforcing component contains a reactive silane that forms chemical bonds with hydroxyl groups on the powder surface. This improves green body strength. The bonding component is a low viscosity epoxy adhesive that cures at medium temperatures. This reduces energy consumption and equipment costs compared to high cure temperatures. The two components are sprayed sequentially on the powder bed to create a green body with enhanced strength and reduced ash residue.

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Improving 3D printing accuracy by detecting and addressing powder layer inhomogeneities during the printing process. The method involves using a modified powder feeder to distribute the powder layer more uniformly. If inhomogeneities are detected, like lack of powder, they are identified and quantified. This allows early detection of problems that cannot be fixed later. The powder layer is then automatically removed and redistributed before solidification to prevent defects in the final printed part.

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High-throughput, high-precision 3D printing of pharmaceutical dosage units like tablets using multiple synchronized printing heads. The system uses a flow distribution module to divide a single flow of printing material into multiple flows that are dispensed by the synchronized printing heads. This allows accurate, consistent printing of multiple dosage units simultaneously while maintaining high throughput. The synchronized heads have adjustable opening amounts to ensure uniform dispensing. The system also has features like stall detection for needle positioning and a push plate to coordinate simultaneous opening/closing.

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A 3D printing system that allows precise deposition of thin layers of powder for 3D printing. The system has a powder feeder with an adjustable blade to flatten the powder as it's deposited. This prevents shear forces that can hinder thin layer formation. A counter-rotating roller compacts the powder at a separate location. Both the blade and roller heights are adjustable. The blade flattens the powder to a consistent thickness and the roller compacts it to the desired layer height. This prevents powder accumulation issues and ensures uniform thin layers. The roller rotates counter to the powder flow to prevent sliding. Vibrating the roller and substrate at a rapid frequency improves powder flowability.

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Binder jetting coaxial powder feeding nozzle for 3D printing that allows uniform powder distribution for better green body formation. The nozzle has a coaxial design with an inner binder channel and an outer powder channel. The powder feeds into the outer channel and collides with helical blades inside the nozzle. This causes the powder to rebound and spiral down, distributing evenly throughout the chamber before exiting through the powder outlet.

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Quantitative powder supply system for 3D printing with adhesive jetting that provides consistent and controlled powder feeding for better print quality. The system uses separate bins and chambers connected in sequence to feed powder from a primary bin to a moving secondary bin, then to a discharging chamber beneath the printer. This sequential powder path allows quantitative feeding without splashing or particle suspension issues. The bins have features like feed inlets, stirring, diversion, and pressing to ensure consistent powder flow.

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A three-dimensional printing system with reduced carbon content in the printed parts. It uses a specialized binder circulation setup to reduce carbon content in the printed parts. The system has separate chambers for the binder, a nozzle to eject the binder, and channels to circulate the binder. The binder contains water, a water-soluble resin, and a wetting agent. The circulation allows continuous flow of the binder and prevents carbon buildup that can occur when the binder sits in the system for long periods. This reduces the carbon content in the printed parts compared to traditional 3D printing systems where the binder sits stagnant.

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A three-dimensional printing system with improved binder circulation to enhance print quality. The system has an ejection head with individual binder chambers that feed through a nozzle. Binder exiting the chambers flows through a separate circulation loop back into the chambers. This recirculation prevents binder degradation, improves stability, and reduces water content compared to open-loop systems. The circulation loop can have flexible sections that deform under pressure to absorb fluctuations. This allows the circulation flow path to match the head geometry without rigid connections.

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Reducing voids in 3D printed parts by compressing the freshly deposited filaments immediately after deposition. The method involves using specially designed members positioned alongside the nozzle that apply compression on the just-printed layers. The members have roller balls that contact the filaments and compress them. This prevents void formation between filaments and improves adhesion. The compression can be adjusted based on material properties and print parameters.

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Calculating the optimal amount of binder to apply at each voxel location in 3D printing to prevent excessive migration and accumulation of binder in the build chamber. The method involves calculating the binder volume needed based on the voxel's surrounding proximate voxels that will also receive the binder. This prevents over-application that could lead to unwanted solidification and defects.

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Additive manufacturing system with a rotating printhead for making complex 3D parts with variable density. The system has a rotating build platform, multiple printheads with varying density binder jets, and a recoater. The platform, printheads, and recoater rotate around the parts during fabrication. This allows consolidating particles at varying densities to form components with internal structures like channels, vents, and protrusions. The rotation enables continuous fabrication and faster build times compared to fixed printheads and recoaters.

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Method for controlling a binder jet printer to reduce issues with excess solvent in printed green bodies. The method involves dispensing binder onto the powder bed in a way that adjusts the binder saturation closer vs further from the shape edges. This prevents overly wet regions causing bleeding through the next layer. The binder saturation near edges is higher than further away. The amount of binder dispensed is adjusted based on distance from edges. This can be done by deactivating nozzles over areas further from edges, reducing droplet frequency, or varying droplet size. The goal is to balance avoiding dry edges vs preventing solvent bleeding.

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3D printing method that allows printing high quality outputs with customizable powder materials. The method involves accurately calculating the amount of binder to spray on the powder bed to fill the voids and prevent defects. The calculation uses measured powder mass to determine the pore volume in the layer. This volume is then used to determine the optimal binder amount to print that layer. By precisely matching the binder to the pore volume, it prevents over- or under-saturation of the powder bed. This allows using a wider range of powder materials with varying densities. The method involves measuring the powder mass for each region, calculating the pore volume, determining the binder amount, and then printing the binder in the calculated pattern.

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Bidirectional powder spreading and printing system for a binder jet 3D printer that reduces waste time and improves efficiency compared to conventional bidirectional printing methods. The system allows simultaneous powder spreading and printing on both sides of the build plate, eliminating idle strokes and waiting between steps. The key features are: 1. Bidirectional linear motion for spreading and printing: The system uses a linear guide with bidirectional movement to allow simultaneous spreading of powder and printing on both sides of the build plate. This avoids wasted time and motion from switching directions. 2. Powder feeding and storage optimization: The powder feeding and storage components are designed to match the printing width and thickness. This prevents unnecessary waste from overfilling or underfilling the powder bed. 3. Multiple inkjet heads and cartridges: The printing part has multiple inkjet heads and cartridges arranged in parallel

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Optimizing the quality of 3D printed objects by controlling the amount of functional agents like binders, fusing agents, and detailing agents applied based on distance from the object surface. This is done using a distance function associated with the distance between a portion of the object and the surface or edge. Adjusting the agent deposition based on proximity reduces issues like lifting, curling, and fabrication artifacts while improving surface definition and stability. This is especially useful for complex shapes with overhangs or nested objects where some areas have a greater distance from the surface.

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