Innovative Solutions for Ensuring Consistent Binder Distribution in 3D Printing

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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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 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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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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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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3D printing materials are specifically formulated to enable the printing of large, strong objects suitable for construction applications. The material is a composite of a base material used in conventional 3D printing, like sand or cement, combined with additives like fine powders, fibers, or aggregates. These additives improve packing, bridge layers, and enhance binding between printed layers to overcome the weaknesses of conventional 3D printed objects.

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Three-dimensional (3D) printing of dimensionally stable printed articles that do not significantly expand or contract after printing. The method involves using specific powder and binder compositions for 3D printing that prevent size changes. The powder contains plaster, lactose, accelerator, lubricant, and colloidal silica. The binder is water, glycerin, and surfactant. The compositions are optimized for 3D printing systems to provide accurate and stable printed articles. The articles can be used to make molds that accurately replicate the printed shapes. The stable mold material prevents mold expansion or contraction during casting.

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A method to strengthen 3D printed components by infiltrating the pores with a material that binds when wet. The method involves printing the component using a partially hydrated binder that sets to a solid when fully hydrated. This allows the printed component to initially have some strength for handling, but it still has pores. Then, the component is immersed in water or sprayed with a water-containing solution. The water infiltrates the pores and solidifies the additional binder, increasing the component's strength. This avoids the issues of long drying times and skin formation that can occur with infiltrating polymers or binders.

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3D printing method that allows controlling the chemical, physical, and mechanical properties of 3D printed objects at each location by precisely controlling the composition of the printed material. The method involves mixing and extruding two or more reactant liquids from separate reservoirs through a scanning nozzle onto the substrate. The relative composition of each liquid is controlled using flow rate adjustment. The mixed liquids are then rapidly solidified by photopolymerization using visible or UV light irradiation. This allows spatially varying the composition of the printed material to create objects with customized properties at each point.

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Producing 3D printed objects with improved mechanical strength by varying the binder application based on layer thickness. The method involves measuring the thickness of each layer after forming, then adjusting the binder amount per area ejected onto the layer based on the measured thickness. This prevents under- or over-binding in thick or thin areas, respectively. The method can be automated using a 3D printer with thickness sensors and binder adjustment capabilities.

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