Consistent Binder Distribution Techniques in 3D Printing

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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3D printing method and apparatus that improves print quality and reduces defects by optimizing the timing of multiple print agent dispensers moving and ejecting materials. The method involves determining the optimal delay between dispensing different print agents at a specific location on a layer. This delay is independently controlled for each dispenser's movement and ejection. It allows coordinating the timing of multiple print heads to generate complex 3D objects without overlaps or gaps. This improves print quality and reduces defects compared to simultaneous ejection.

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Method and system for 3D printing concrete using curable binder compositions like concrete or mortar for producing 3D printed concrete objects with improved quality and reliability compared to conventional 3D printing methods. The method involves continuously measuring pressure drop, flow rate, torque, and optionally temperature in the supply line and mixer during printing to monitor rheological properties in real-time. This allows detecting deviations and initiating actions to keep parameters within target ranges. It also enables determining viscosities from pressure drops.

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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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Improved accuracy in 3D printing objects from powders and binding liquid using separate suppressant liquid to prevent excessive spread of the binding liquid outside the desired region. This allows precise shaping of features without blurring or bulging. The suppressant liquid is applied adjacent to the shaping region to contain the binding liquid.

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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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3D printing method to improve the strength and bonding of printed parts by interlayer stitching. The method involves forming an interlayer binding layer between adjacent layers during 3D printing. The binding layer extends into both lower and upper layers. It uses a one-dimensional material like carbon nanotubes or metal fibers that are injected into the lower layer and then extend into the upper layer when printing. This interlayer stitching significantly improves the bonding force and effect between layers, which enhances the overall strength of 3D printed parts.

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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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