Recoating assembly for an additive manufacturing system and method of use thereof

Abstract

A method for forming an object, comprising: moving a recoat assembly (200) in a coating direction over a build material, wherein the recoat assembly (200) comprises a first roller (202) and a second roller (204) spaced apart from the first roller; rotating the first roller (202) of the recoat assembly in a counter-rotation direction such that a bottom of the first roller moves in the coating direction; contacting the build material with the first roller of the recoat assembly, thereby fluidizing at least a portion of the build material; irradiating an initial layer of build material positioned in a build area with a front energy source (260) coupled to a front end of the recoat assembly; after irradiating the initial layer of build material, spreading the build material over the build area with the first roller, thereby depositing a second layer of build material on the initial layer of build material; and after spreading the second layer of build material, irradiating the second layer of build material within the build area with a back energy source (262) positioned behind the front energy source.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 61 / 851,954, filed May 23, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to additive manufacturing systems, and more specifically, to recoating components designed for additive manufacturing systems and methods of using them. Background Technology

[0004] Additive manufacturing systems can be used to "build" objects from build materials (such as organic or inorganic powders) in a layered manner. Traditional additive manufacturing systems include various "recoating" devices configured to sequentially distribute layers of build material, allowing binder materials to deposit and cure to "build" the object. However, traditional recoating devices may distribute the build material inconsistently, leading to variations in the objects built by the additive manufacturing system. Furthermore, if a component of a traditional recoating device breaks, the device typically needs to be removed for repair, increasing system downtime and operating costs. Additionally, some traditional recoating devices distribute the build material by fluidizing it, and airborne build material can disperse into other components of the additive manufacturing system, potentially interfering with and / or degrading those components.

[0005] Therefore, there is a need for alternative recoating components for additive manufacturing systems. Summary of the Invention

[0006] In one embodiment, a method for forming an object includes: moving a recoating assembly over a build material in a coating direction, wherein the recoating assembly includes a first roller and a second roller spaced apart from the first roller; rotating the first roller of the recoating assembly in a counter-rotation direction such that the bottom of the first roller moves in the coating direction; contacting the build material with the first roller of the recoating assembly, thereby fluidizing at least a portion of the build material; irradiating an initial layer of build material located within a build region with a front energy source coupled to the front end of the recoating assembly; after irradiating the initial layer of build material, spreading the build material over the build region with the first roller, thereby depositing a second layer of build material over the initial layer of build material; and after spreading the second layer of build material, irradiating the second layer of build material within the build region with a rear energy source located behind the front energy source.

[0007] In another embodiment, the method for forming an object includes moving a recoating assembly over a build material, wherein the recoating assembly includes a first roller and a second roller spaced apart from the first roller; moving the second roller above the first roller in a vertical direction; rotating the first roller of the recoating assembly in an anti-rotational direction such that the bottom of the first roller moves in a coating direction; contacting the build material with the first roller of the recoating assembly to fluidize at least a portion of the build material, while the second roller is spaced apart from the build material in a vertical direction; and moving the fluidized build material together with the first roller to deposit a second layer of build material on an initial layer of build material positioned in a build region.

[0008] In yet another embodiment, the recoating assembly for an additive manufacturing system includes a substrate member, a front roller rotatably coupled to the substrate member, a rear roller rotatably coupled to the substrate member, a front energy source coupled to the substrate member and positioned in front of the front roller, and a rear energy source coupled to the substrate member and positioned behind the front energy source, wherein the front roller and the rear roller are spaced apart, wherein the front energy source emits energy in front of the front roller, and wherein the rear energy source emits energy behind the front energy source.

[0009] In yet another embodiment, a recoating assembly for an additive manufacturing system includes a substrate member, a first roller rotatably coupled to the substrate member, and a second roller rotatably coupled to the substrate member, the first roller having a first roller diameter, wherein the second roller is spaced apart from the first roller and has a second roller diameter, wherein the second roller diameter is larger than the first roller diameter.

[0010] Additional features and advantages of the additive manufacturing equipment and components described herein will be set forth in the following detailed description and will become apparent in part to those skilled in the art from the description or by practicing the embodiments described herein, including the following detailed description, claims and drawings.

[0011] It should be understood that the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, serve to explain the principles and operation of the claimed subject matter. Attached Figure Description

[0012] Figure 1 A schematic depiction of a conventional additive manufacturing system;

[0013] Figure 2A An additive manufacturing system according to one or more embodiments shown and described herein is schematically depicted;

[0014] Figure 2BAnother additive manufacturing system is schematically depicted according to one or more embodiments shown and described herein;

[0015] Figure 2C An enlarged view schematically depicting the building material of an additive manufacturing system according to one or more embodiments shown and described herein;

[0016] Figure 3 The illustration schematically depicts one or more embodiments shown and described herein. Figure 2A An embodiment of a recoating component for an additive manufacturing system;

[0017] Figure 4 The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 Another view of the repainted component;

[0018] Figure 5 The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 Another view of the repainted component;

[0019] Figure 6A Another side view of the repainting assembly according to one or more embodiments shown and described herein is schematically depicted;

[0020] Figure 6B A cross-sectional view of a repainting assembly according to one or more embodiments shown and described herein is schematically depicted;

[0021] Figure 6C An isolated display according to one or more embodiments shown and described herein is schematically depicted. Figure 6B The rollers and roller supports of the recoating assembly;

[0022] Figure 7A An isolated configuration based on one or more embodiments shown and described herein is schematically depicted. Figure 6C Roller support;

[0023] Figure 7B The illustration schematically depicts one or more embodiments shown and described herein. Figure 7A Another view of the roller support;

[0024] Figure 7C The illustration schematically depicts one or more embodiments shown and described herein for use with Figure 7A The strain gauge of the roller support; and

[0025] Figure 8 An isolated additional roller support is schematically depicted according to one or more embodiments shown and described herein;

[0026] Figure 9A An isolated additional roller support is schematically depicted according to one or more embodiments shown and described herein;

[0027] Figure 9B The illustration schematically depicts one or more embodiments shown and described herein. Figure 9A Another view of the roller support;

[0028] Figure 9C The illustration schematically depicts one or more embodiments shown and described herein. Figure 9A A cross-sectional view of the roller support;

[0029] Figure 9D The illustration schematically depicts a method for using with one or more embodiments shown and described herein. Figure 9A A load sensor used in conjunction with a roller support;

[0030] Figure 10 A roller support coupled to a load sensor and at least one strain gauge is schematically depicted according to one or more embodiments shown and described herein;

[0031] Figure 11A The illustration schematically depicts one or more embodiments shown and described herein. Figure 6B Another cross-sectional view of the repainted component;

[0032] Figure 11B A perspective view of a repainting assembly according to one or more embodiments shown and described herein is schematically depicted;

[0033] Figure 11C The illustration schematically depicts one or more embodiments shown and described herein. Figure 11B A perspective cross-sectional view of the repainted component;

[0034] Figure 11D The illustration schematically depicts one or more embodiments shown and described herein. Figure 11B Cross-sectional view of the repainted component;

[0035] Figure 11E A bottom perspective view of a repainting assembly according to one or more embodiments shown and described herein is schematically depicted;

[0036] Figure 12 The illustration schematically depicts one or more embodiments shown and described herein. Figure 6B The rollers and energy source for the recoating components;

[0037] Figure 13 The illustration schematically depicts one or more embodiments shown and described herein. Figure 6B An embodiment of the roller layout for a recoating assembly;

[0038] Figure 14 The illustration schematically depicts one or more embodiments shown and described herein. Figure 6B Another embodiment of the roller layout for the recoating assembly;

[0039] Figure 15 The illustration schematically depicts one or more embodiments shown and described herein. Figure 6B Another embodiment of the roller layout for the recoating assembly;

[0040] Figure 16A A perspective view of a repainting assembly including a cleaning component, according to one or more embodiments shown and described herein, is schematically depicted.

[0041] Figure 16B A perspective view of a repainting assembly including a cleaning component, according to one or more embodiments shown and described herein, is schematically depicted.

[0042] Figure 16C The illustration schematically depicts one or more embodiments shown and described herein. Figure 16B A perspective cross-sectional view of the repainted component;

[0043] Figure 16D The illustration schematically depicts one or more embodiments shown and described herein. Figure 16C A cross-sectional view of the cleaning position adjustment assembly of the cleaning component joint;

[0044] Figure 17A The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 A top view of the cleaning components and rollers of the recoating assembly;

[0045] Figure 17B The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 Another top view of the recoating assembly's rollers and cleaning components;

[0046] Figure 17C The illustration schematically depicts one or more embodiments according to those shown and described herein. Figure 3 Side view of the rollers and cleaning components of the recoating assembly;

[0047] Figure 18A The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 A perspective view of the secondary containment housing and vacuum section of the recoating assembly;

[0048] Figure 18BThe illustration schematically depicts one or more embodiments shown and described herein. Figure 3 A perspective view of the primary containment housing and vacuum section of the recoating assembly;

[0049] Figure 19 The vacuum section and vacuum unit according to one or more embodiments shown and described herein are schematically depicted. Figure 3 A cross-sectional view of the repainted component;

[0050] Figure 20 A perspective view of another repainting component according to one or more embodiments shown and described herein is schematically depicted.

[0051] Figure 21 The illustration schematically depicts one or more embodiments shown and described herein. Figure 20 Another perspective view of the repainted component;

[0052] Figure 22 The illustration schematically depicts one or more embodiments shown and described herein. Figure 20 A cross-sectional view of the repainted component;

[0053] Figure 23 Another cross-sectional view of the repainting assembly according to one or more embodiments shown and described herein is schematically depicted;

[0054] Figure 24 A control diagram of an additive manufacturing system according to one or more embodiments shown and described herein is schematically depicted;

[0055] Figure 25 It is a flowchart of adjusting operating parameters of an additive manufacturing system according to one or more embodiments shown and described herein;

[0056] Figure 26 This is another flowchart illustrating the adjustment of operating parameters of an additive manufacturing system according to one or more embodiments shown and described herein;

[0057] Figure 27 It is a flowchart of moving building material to a building region according to one or more embodiments shown and described herein;

[0058] Figure 28 A recoating assembly according to one or more embodiments shown and described herein is schematically depicted to move build material into the build area;

[0059] Figure 29A A recoating assembly according to one or more embodiments shown and described herein is schematically depicted to move build material into the build area;

[0060] Figure 29BA schematic depiction of a recoating component compacted within a build area according to one or more embodiments shown and described herein;

[0061] Figure 29C A recoating assembly according to one or more embodiments shown and described herein is schematically depicted to move build material into the build area;

[0062] Figure 29D The repainting component, according to one or more embodiments shown and described herein, is schematically depicted moving in the return direction; and

[0063] Figure 30 This is a flowchart of a method for extracting build material from a repainting component according to one or more embodiments shown and described herein. Detailed Implementation

[0064] Reference will now be made in detail to embodiments of additive manufacturing equipment and components thereof, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. One embodiment of the additive manufacturing system 100 is schematically depicted in… Figure 2A Additive manufacturing systems generally include a recoating assembly for spreading build material in a build area. In the embodiments described herein, the recoating assembly includes one or more sensors that detect forces acting on the recoating assembly. By detecting the forces acting on the recoating assembly, defects can be identified, and one or more parameters related to the operation of the recoating assembly can be adjusted to optimize the performance of the recoating assembly. In some embodiments, the recoating assembly described herein may include multiple redundant components, such as rollers and power sources, so that the recoating assembly can continue to operate in the event of a failure of one or more components. In some embodiments, the recoating assembly described herein is fluidly connected to a vacuum unit that collects and contains build material in the air. These and other embodiments of recoating assemblies for additive manufacturing systems, additive manufacturing systems including recoating assemblies, and methods of using these assemblies will be described in further detail herein with specific reference to the accompanying drawings.

[0065] In this text, a range may be expressed as from “about” a specific value and / or to “about” another specific value. When such a range is expressed, another embodiment includes from the one specific value and / or to the other specific value. Similarly, when a value is expressed as an approximation, it will be understood, by using the antecedent “about,” that specific value forms another embodiment. It will be further understood that each endpoint of a range is significant relative to the other endpoint and independent of the other endpoint.

[0066] The directional terms used in this document—such as up, down, right, left, front, back, top, and bottom—are for reference only and are not intended to imply absolute orientation unless otherwise explicitly stated.

[0067] The phrase "communicatively connected" is used here to describe the interconnectivity of various components and means that these components are connected by wires, optical fibers or wirelessly, so that electrical, optical and / or electromagnetic signals can be exchanged between the components.

[0068] Unless otherwise expressly stated, no method described herein is intended to be construed as requiring its steps to be performed in a particular order, nor is it intended to require any particular orientation of the device. Therefore, if a method claim does not actually describe the order in which its steps are followed, or any device claim does not actually describe the order or orientation of individual components, or unless there is a separate specific statement in the claims or description that the steps are subject to a particular order, or a particular order or orientation of the device's components is not described, then no order or orientation is to be inferred in any way. This applies to any possible non-explicit basis of interpretation, including: logical questions concerning the arrangement of steps, the flow of operations, the order of components, or the orientation of components; simple meanings derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0069] Unless the context clearly indicates otherwise, the singular forms “a,” “one,” and “the” used in this text include plural references. Thus, for example, a reference to the component “a” includes aspects having more than two such components, unless the context clearly indicates otherwise.

[0070] The embodiments described herein are generally geared towards recoated components for use in additive manufacturing systems. Additive manufacturing systems typically "build" materials by continuously depositing and bonding build materials. In conventional additive manufacturing systems, the deposition of build materials is a difficult, messy, time-consuming, and error-prone process. The embodiments described herein are for recoated components that deposit build materials in a consistent and configurable manner.

[0071] Now for reference Figure 1A conventional additive manufacturing system 10 is schematically depicted. The conventional additive manufacturing equipment 10 includes a feed platform 30, a build platform 20, a cleaning station 11, and a build head 15. The feed platform 30 is coupled to a feed platform actuator 32. The feed platform actuator 32 is actuated in the vertical direction (i.e., the + / -Z direction of the coordinate axes depicted in the figure), allowing the feed platform 30 to be raised or lowered. The build platform 20 is positioned adjacent to the feed platform 30 and, similar to the feed platform 30, is coupled to an actuator, specifically, to the build platform actuator 22. The build platform actuator 22 is actuated in the vertical direction, allowing the build platform 20 to be raised or lowered. The cleaning station 11 is positioned adjacent to the feed platform 30, opposite to the build platform 20. That is, along the working axis of the conventional additive manufacturing equipment 10 (i.e., the axis extending parallel to the + / -X axis of the coordinate axes depicted in the figure), the feed platform 30 is positioned between the cleaning station 11 and the build platform 20. The build head 15 can be traversed along the working axis of a conventional additive manufacturing equipment 10 using an actuator (not shown), so that the build head 15 moves from its original position 12, which is adjacent to the cleaning station 11, through the supply platform 30, through the build platform 20, and back to the original position 12.

[0072] During operation, build material 31 (such as organic or inorganic powder) is positioned on the supply platform 30. The supply platform 30 is actuated to present a layer of build material 31 in the path of the build head 15. Then, in the direction indicated by arrow 40, the build head 15 is actuated from the original position 12 toward the build platform 20 along the working axis of a conventional additive manufacturing apparatus 10. As the build head 15 traverses the supply platform 30 toward the build platform 20, the build head 15 distributes a layer of build material 31 in its path from the supply platform 30 to the build platform 20. Subsequently, as the build head 15 continues along the working axis on the build platform 20, the build head 15 deposits a layer of binder material 50 in a predetermined pattern on the layer of build material 31 already distributed on the build platform 20. Optionally, after depositing the binder material 50, energy within the build head 15 is used to cure the deposited binder material 50. The build head 15 then returns to its original position 12, where at least a portion of the build head 15 is positioned on the cleaning station 11. While in its original position 12, the build head 15, together with the cleaning station 11, performs cleaning and maintenance operations on the components of the build head 15 depositing the adhesive material 50, ensuring that the components are not contaminated or otherwise clogged. This ensures that the build head can deposit the adhesive material 50 in the desired pattern during subsequent deposition cycles. During this maintenance interval, as indicated by arrow 43, the supply platform 30 is actuated in the upward vertical direction (i.e., the +Z direction of the coordinate axis depicted in the figure) to present a new layer of build material 31 in the path of the build head 15. As indicated by arrow 42, the build platform 20 is actuated in the downward vertical direction (i.e., the -Z direction of the coordinate axis depicted in the figure) to prepare the build platform 20 to receive a new layer of build material 31 from the supply platform 30. Then, the build head 15 is actuated along the working axis of the conventional additive manufacturing equipment 10 to add another layer of build material 31 and adhesive material 50 to the build platform 20. This sequence of steps is repeated several times to build an object on the build platform 20 in a layered manner.

[0073] Now for reference Figure 2AAn embodiment of an additive manufacturing system 100 is schematically depicted. System 100 includes a cleaning station 110, a build area 124, a supply platform 130, and an actuator assembly 102. Among other elements, actuator assembly 102 includes a recoating assembly 200 for distributing build material 31 and a printhead 150 for depositing binder material 50. Actuator assembly 102 is configured to allow independent traversal of the recoating assembly 200 and printhead 150 along the working axis of system 100. This allows at least some steps of the additive manufacturing process to be performed synchronously, thereby reducing the total cycle time of the additive manufacturing process to less than the sum of the cycle times for each individual step. In the embodiment of system 100 described herein, the working axis 116 of system 100 is parallel to the + / - X-axis of the coordinate axes depicted in the figure. It should be understood that components of the additive manufacturing system 100 traversing the working axis 116 (such as the recoating head 140, printhead 150, etc.) do not need to be centered on the working axis 116. However, in the embodiments described herein, at least two components of the additive manufacturing system 100 are arranged relative to the working axis 116 such that, if not properly controlled, the components could occupy the same or overlapping volume along the working axis when they traverse the working axis.

[0074] In the embodiments described herein, the cleaning station 110, build platform 120, and supply platform 130 are positioned in series along the working axis 116 of the system 100 between the print origin position 158 of the print head 150 and the recoating origin position 148 of the recoating assembly 200. The print origin position 158 is located near one end of the working axis 116 in the -X direction, and the recoating origin position 148 is located near one end of the working axis 116 in the +X direction. That is, the print origin position 158 and the recoating origin position 148 are spaced apart from each other in a horizontal direction parallel to the + / -X axis of the coordinate axis depicted in the figures, and the cleaning station 110, build area 124, and supply platform 130 are positioned between them. In the embodiments described herein, the build area 124 is positioned along the working axis 116 of the system 100 between the cleaning station 110 and the supply platform 130.

[0075] Cleaning station 110 is located near one end of the working axis 116 of system 100 and juxtaposed with the print origin position 158. Before and after the deposition of adhesive material 50 on a layer of build material 31 positioned on build area 124, the print head 150 is positioned or "parked" in the print origin position 158. Cleaning station 110 may include more than one cleaning section (not shown) to facilitate cleaning of print head 150 between deposition operations. The cleaning section may include, for example, but not limited to, a soaking station, a wiping station, a spraying station, a parking station, or a combination thereof. The soaking station contains a cleaning solution for dissolving excess adhesive material on print head 150; the wiping station is used to remove excess adhesive material from print head 150; the spraying station is used to remove adhesive material and cleaning solution from print head 150; and the parking station is used to maintain moisture in the nozzles of print head 150. Print head 150 can be switched between cleaning sections via actuator assembly 102.

[0076] While this document refers to an additive manufacturing system that includes a printhead 150 dispensing adhesive material 50, it should be understood that the recoating assembly 200 described herein can be used with other suitable additive powder-based additive manufacturing systems. For example, instead of using cured adhesive 50 applied to build material 31 to build an object, in some embodiments, a laser or other energy source may be applied to build material 31 to melt build material 31.

[0077] exist Figure 2AIn the described embodiment, the build region 124 includes a reservoir comprising a build platform 120. The build platform 120 is coupled to a build platform actuator 122 to raise and lower the build platform 120 relative to the operating axis 116 of the system 100 in a vertical direction (i.e., a direction parallel to the + / -Z direction of the coordinate axes depicted in the figure). The build platform actuator 122 may be, for example, but not limited to, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, or any other actuator suitable for imparting linear motion to the build platform 120 in a vertical direction. Suitable actuators may include, but are not limited to, worm gear actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, etc. The build platform 120 and the build platform actuator 122 are positioned in the build region 124, located below the operating axis 116 of the system 100 (i.e., in the -Z direction of the coordinate axes depicted in the figure). During operation of system 100, after each layer of adhesive material 50 is deposited on the build material 31 positioned on build platform 120, build platform 120 retracts into build region 124 by action of build platform actuator 122. Although build region 124 described and depicted herein includes a reservoir, it should be understood that build region 124 may include any suitable structure for supporting build material 31 and may include, for example, a simple surface supporting build material 31.

[0078] The supply platform 130 is coupled to the supply platform actuator 132 to raise and lower the supply platform 130 relative to the working axis 116 of the system 100 in the vertical direction (i.e., in the direction parallel to the + / -Z direction of the coordinate axis depicted in the figure). The supply platform actuator 132 can be, for example, but not limited to, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, or any other actuator suitable for imparting linear motion to the supply platform 130 in the vertical direction. Suitable actuators can include, but are not limited to, worm gear actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, etc. The supply platform 130 and the supply platform actuator 132 are positioned in the supply reservoir 134, located below the working axis 116 of the system 100 (i.e., in the -Z direction of the coordinate axis depicted in the figure). During operation of system 100, after a layer of building material 31 is distributed from supply platform 130 to building platform 120, supply platform 130 is raised relative to supply reservoir 134 toward the working axis 116 of system 100 by the action of supply platform actuator 132, as will be described in further detail herein.

[0079] In one embodiment, actuator assembly 102 generally includes a recoating assembly lateral actuator 144, a printhead actuator 154, a first guide 182, and a second guide 184. The recoating assembly lateral actuator 144 is operatively coupled to the recoating assembly 200 and operable to move the recoating assembly 200 relative to the build platform 120 to dispense build material 31 onto the build platform 120, as described in more detail herein. The printhead actuator 154 is operatively coupled to the printhead 150 and operable to move the printhead 150 relative to the build platform 120 to dispense adhesive material 50 onto the build platform 120.

[0080] In the embodiments described herein, the first guide 182 and the second guide 184 extend in a horizontal direction parallel to the operating axis 116 of the system 100 (i.e., parallel to the + / -X direction of the coordinate axes depicted in the figures) and are spaced apart from each other in a vertical direction. When the actuator assembly 102 as Figure 2A When positioned on the cleaning station 110, the construction platform 120, and the supply platform 130 as described, the first guide 182 and the second guide 184 extend horizontally from the cleaning station 110 beyond the supply platform 130.

[0081] In embodiments, such as Figure 2A In one embodiment of the actuator assembly 102 depicted, the first guide 182 and the second guide 184 are opposite sides of a rail 180 that extends horizontally and is oriented such that the first guide 182 is positioned on and spaced apart from the second guide 184. For example, in one embodiment, the rail 180 has an "I" configuration in a vertical cross-section (i.e., a cross-section in the YZ plane of the coordinate axes depicted in the figure), wherein the upper and lower flanges of the "I" form the first guide 182 and the second guide 184, respectively. However, it should be understood that other embodiments are conceivable and possible. For example, but not limited to, the first guide 182 and the second guide 184 can be separate structures, such as separate rails, extending horizontally and spaced apart from each other in the vertical direction. In some embodiments, the first guide 182 and the second guide 184 can be positioned at the same height and spaced apart from each other on opposite sides of the rail 180. In an embodiment, the first guide 182 and the second guide 184 are positioned in any suitable configuration and may be collinear.

[0082] In the embodiments described herein, the recoating assembly lateral actuator 144 is coupled to one of the first guide 182 and the second guide 184, and the printhead actuator 154 is coupled to the other of the first guide 182 and the second guide 184, such that the recoating assembly lateral actuator 144 and the printhead actuator 154 are arranged in a "stacked" configuration. For example, in Figure 2A In the embodiment of actuator assembly 102 depicted, the recoating assembly lateral actuator 144 is coupled to the second guide 184, and the printhead actuator 154 is coupled to the first guide 182. However, it should be understood that in other embodiments (not depicted), the recoating assembly lateral actuator 144 may be coupled to the first guide 182, and the printhead actuator 154 may be coupled to the second guide 184.

[0083] In the embodiments described herein, the recoating assembly lateral actuator 144 is bidirectionally actuated along the recoating motion axis 146, and the printhead actuator 154 is bidirectionally actuated along the printing motion axis 156. That is, the recoating motion axis 146 and the printing motion axis 156 respectively define the axes along which the recoating assembly lateral actuator 144 and the printhead actuator 154 are actuated. The recoating motion axis 146 and the printing motion axis 156 extend in the horizontal direction and are parallel to the operating axis 116 of the system 100. In the embodiments described herein, due to the stacked configuration of the recoating assembly lateral actuator 144 and the printhead actuator 154, the recoating motion axis 146 and the printing motion axis 156 are parallel to each other and spaced apart from each other in the vertical direction. In some embodiments, such as Figure 2A In the embodiment of the actuator assembly 102 depicted, the repainting motion axis 146 and the printing motion axis 156 are located in the same vertical plane (i.e., a plane parallel to the XZ plane of the coordinate axes depicted in the figure). However, it should be understood that other embodiments are conceivable and possible, such as embodiments in which the repainting motion axis 146 and the printing motion axis 156 are located in different vertical planes.

[0084] In the embodiments described herein, the recoating assembly lateral actuator 144 and the printhead actuator 154 can be, for example, but not limited to, mechanical actuators, electromechanical actuators, pneumatic actuators, hydraulic actuators, or any other actuator suitable for providing linear motion. Suitable actuators may include, but are not limited to, worm gear actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, and the like. In one particular embodiment, the recoating assembly lateral actuator 144 and the printhead actuator 154 are manufactured by Pittsburgh, Pennsylvania. Inc. manufactures linear actuators such as PR0225LM mechanical bearings and linear motor stages.

[0085] In embodiments, the recoating head actuator 144 and the printhead actuator 154 may each be a cohesive subsystem fixed to the guide rail 180, such as when the recoating head actuator 144 and the printhead actuator 154 are, for example, PR0225LM mechanical bearings or linear motor stages. However, it should be understood that other embodiments are conceivable and possible, such as embodiments where the recoating head actuator 144 and the printhead actuator 154 comprise several components respectively assembled onto the guide rail 180 to form the recoating head actuator 144 and the printhead actuator 154.

[0086] Still refer to Figure 2A The recoating assembly 200 is connected to the recoating assembly lateral actuator 144, positioning the recoating assembly 200 below the first guide 182 and the second guide 184 (i.e., in the -Z direction of the coordinate axis depicted in the figure). When the actuator assembly 102 is positioned on the cleaning station 110, the build platform 120, and the supply platform 130, as... Figure 2A As described, the recoating assembly 200 is located on the operating axis 116 of the system 100. Therefore, the bidirectional actuation of the recoating assembly lateral actuator 144 along the recoating motion axis 146 affects the bidirectional movement of the recoating assembly 200 on the operating axis 116 of the system 100. Figure 2A In embodiments of actuator assembly 102 described herein, recoating assembly 200 is connected to recoating assembly lateral actuator 144 via support bracket 176, thereby positioning recoating assembly 200 on the working axis 116 of system 100 while still providing clearance between the track 180 of actuator assembly 102 and build platform 120 and supply platform 130. In some embodiments described herein, recoating assembly 200 may be fixed in a direction orthogonal to recoating motion axis 146 and working axis 116 (i.e., fixed along + / - Z axis and / or along + / - Y axis).

[0087] Similarly, printhead 150 is coupled to printhead actuator 154, positioning printhead 150 below the first guide 182 and the second guide 184 (i.e., in the -Z direction of the coordinate axis depicted in the figure). When actuator assembly 102 as... Figure 2A When positioned as described in the description on the cleaning station 110, build platform 120, and supply platform 130, the printhead 150 is located on the working axis 116 of the system 100. Therefore, bidirectional actuation of the printhead actuator 154 along the printing motion axis 156 affects the bidirectional movement of the printhead 150 on the working axis 116 of the system 100. Figure 2AIn embodiments of the actuator assembly 102 described herein, the printhead 150 is coupled to the printhead actuator 154 via a support bracket 174, thereby positioning the printhead 150 on the working axis 116 of the system 100 while still providing clearance between the track 180 of the actuator assembly 102 and the build platform 120 and the supply platform 130. In some embodiments described herein, the printhead 150 may be fixed in a direction orthogonal to the printing motion axis 156 and the working axis 116 (i.e., fixed along the + / - Z axis and / or along the + / - Y axis).

[0088] Although Figure 2A An embodiment of actuator assembly 102 is illustrated schematically, including a first guide 182 and a second guide 184, on which a recoating assembly lateral actuator 144 and a printhead actuator 154 are respectively mounted. However, it should be understood that other embodiments are conceivable and possible, such as embodiments including more than two guides and more than two actuators. It should also be understood that other embodiments are conceivable and possible, such as embodiments including a printhead and recoating assembly 200 on the same actuator.

[0089] Reference Figure 2B In some embodiments, the additive manufacturing system 100 includes a cleaning station 110 and a build area 124, as described herein. Figure 2A Described. However, in Figure 2B In the depicted embodiment, the additive manufacturing system does not include a supply reservoir. Instead, the system includes a build material hopper 360 for supplying build material 31 to the build region 124. In this embodiment, the build material hopper 360 is coupled to a recoating assembly lateral actuator 144, thereby causing the build material hopper 360 to traverse along the recoating motion axis 146 with the recoating assembly 200. Figure 2B In the described embodiment, the build material hopper 360 is connected to the support bracket 176 via, for example, a bracket 361. However, it should be understood that the build material hopper 360 can be directly connected to the support bracket 176 without an intermediate bracket. Alternatively, the build material hopper 360 can be directly or via an intermediate bracket connected to the recoating assembly 200.

[0090] The build material hopper 360 may include an electrically actuated valve (not depicted) to release build material 31 onto the build region 124 as the build material hopper 360 traverses the build region 124. In an embodiment, the valve may be communicatively coupled to an electrical control unit 300. Figure 24The electrical control unit 300 executes computer-readable and executable instructions to open and close the valve based on the position of the build material hopper 360 relative to the build region. Then, as the recoating assembly 200 traverses the build region 124, the build material 31 released onto the build region 124 is distributed on the build region 124 by the recoating assembly 200.

[0091] Reference Figure 2C To form the object, the material layers 31AA-31DD can be positioned sequentially on top of each other. Figure 2C In the provided example, continuous adhesive layers 50AA-50CC are positioned on the building material layers 31AA-31DD. The finished product can be formed by curing the adhesive layers 50AA-50CC.

[0092] refer to Figure 3 The diagram schematically depicts a perspective view of one embodiment of a recoating assembly 200. In this embodiment, the recoating assembly 200 may include one or more housings 222, 224 that at least partially enclose a portion of the recoating assembly 200. The recoating assembly 200 includes a recoating assembly lateral actuator 144 that moves the recoating assembly 200 in a lateral direction (i.e., in the depicted X direction). In some embodiments, the recoating assembly 200 further includes a recoating assembly vertical actuator 160 that moves the recoating assembly 200 in a vertical direction (i.e., in the depicted Z direction).

[0093] In some embodiments, the recoating assembly 200 includes a base member 250 to which a recoating assembly lateral actuator 144 is coupled to move the base member 250 in a lateral direction (i.e., in the X direction as depicted). As referenced herein, the base member 250 may include any suitable structure of the recoating assembly 200 coupled to the recoating assembly lateral actuator 144, and may include a housing, a plate, etc. Figure 3 and Figure 4 In the embodiment depicted, the recoating assembly 200 further includes at least one tilt actuator 164, which is operable to tilt the base member 250 of the recoating assembly 200 (e.g., about an axis extending in the X direction, such as...). Figure 4 (As depicted herein). As described in more detail herein, in an embodiment, the tilt actuator 164 can tilt the base member 250 of the recoating assembly 200. In an embodiment, the tilt actuator 164 can also tilt the base member 250 to provide access to the underside of the recoating assembly 200, enabling maintenance of the recoating assembly 200.

[0094] refer to Figure 3 and Figure 5In some embodiments, the recoating assembly 200 further includes a base member rotary actuator 162 coupled to the base member 250. The base member rotary actuator 162 is operable to rotate the base member 250 about an axis extending in a vertical direction (e.g., in the depicted Z direction). In embodiments, the base member rotary actuator 162 and the tilt actuator 164 may include any suitable actuator, such as, but not limited to, a worm gear actuator, a ball screw actuator, a pneumatic piston, a hydraulic piston, an electromechanical linear actuator, and the like.

[0095] In some embodiments, reference Figure 4 and Figure 6A The recoating assembly 200 may include a tilt locking member 161 capable of selectively engaging with the base member 250. For example, the tilt locking member 161 may selectively restrict the base member 250 around... Figure 4 The movement of the X-axis is shown in the diagram. By selectively restricting the movement of the base member 250, the orientation of the base member 250 can be maintained, while the tilt actuator 164 applies no force. In this way, the base member 250 can be maintained in... Figure 4 The tilt position shown in the figure allows for maintenance of the recoating assembly 200 without requiring energy to be applied to the tilt actuator 164. In some embodiments, the recoating assembly 200 further includes a first rotation locking member 163 and / or a second rotation locking member 165. The first rotation locking member 163 and / or the second rotation locking member 165 can selectively restrict the base member 250 around... Figure 4 The movement of the Z-axis depicted in the diagram. In an embodiment, the recoating assembly 200 includes a distributed building material 31 ( Figure 2A Powder spreading components, such as one or more rollers.

[0096] For example, refer to Figure 6B and Figure 6C The diagrams depict a side view of the recoating assembly 200 and views of the rollers 202 and 204 of the recoating assembly 200. In an embodiment, the recoating assembly 200 includes a first roller support 210, a second roller support 212, and a first roller 202, which is disposed between and supported by the first roller support 210 and the second roller support 212. Figure 6B and Figure 6CIn the embodiments depicted, the recoating assembly 200 further includes a third roller support 216, a fourth roller support 218, and a second roller 204, the second roller 204 being disposed between and supported by the third roller support 216 and the fourth roller support 218. In these embodiments, the second roller 204 is positioned behind the first roller 202 (i.e., in the depicted -X direction). In these embodiments, the first roller 202 may generally be referred to as the "front" roller, and the second roller 204 may be referred to as the "rear" roller.

[0097] In an embodiment, the recoating assembly 200 includes a roller vertical actuator 252 coupled to a first roller 202 and / or a second roller 204. The roller vertical actuator 252 is operable to move the first roller 202 and / or the second roller 204 relative to the substrate member 250 in a vertical direction (i.e., in the depicted Z direction). In some embodiments, the vertical actuator 252 is coupled to a front roller 202 and a rear roller 204 such that the front roller 202 and the rear roller 204 can move independently of each other relative to the substrate member 250. In some embodiments, the roller vertical actuator 252 is a first roller vertical actuator 252 coupled to the first roller 202, and the recoating assembly 200 further includes a second roller vertical actuator 254 coupled to the second roller 204 such that the front roller 202 and the rear roller 204 can move independently of each other relative to the substrate member 250. The first roller vertical actuator 252 and the second roller vertical actuator 254 may include any suitable actuator, such as, but not limited to, pneumatic actuators, motors, hydraulic actuators, etc.

[0098] The recoating assembly 200 further includes a first rotary actuator 206 coupled to the first roller 202, such as Figure 11B As best illustrated in the diagram. In some embodiments, the first rotary actuator 206 is spaced apart from the first roller 202 and can be coupled to the first roller 202 via a belt, chain, etc. In embodiments where the recoating assembly 200 includes a second roller 204, the recoating assembly 200 may include a second rotary actuator 208 coupled to the second roller 204, such as... Figure 11B As best illustrated in the diagram. In some embodiments, the second rotary actuator 208 is spaced apart from the second roller 204 and can be coupled to the second roller 204 via a belt, chain, etc. In some embodiments, the recoating assembly 200 may include a single rotary actuator coupled to both the first roller 202 and the second roller 204. In some embodiments, the first rotary actuator 206 is directly coupled to the first roller 202, and / or the second rotary actuator 208 is directly coupled to the second roller 204.

[0099] A first rotary actuator 206 is configured to rotate a first roller 202 about a first rotation axis 226. Similarly, a second rotary actuator 208 is configured to rotate a second roller 204 about a second rotation axis 228. Figure 6C In the embodiment depicted herein, the first axis of rotation 226 and the second axis of rotation 228 are substantially parallel to each other and spaced apart from each other in the depicted X direction. As described in more detail herein, the first roller 202 and the second roller 204 may be in the "direction of rotation" (e.g., from...). Figure 6C The viewpoint shown is clockwise) and / or in the "reverse rotation direction" (e.g., from the opposite direction of rotation) Figure 6C Rotation is shown in the viewpoint shown (counterclockwise). The first roller 202 and the second roller 204 can rotate in the same direction or in opposite directions. The first rotary actuator 206 and the second rotary actuator 208 may include any suitable actuator for causing rotation of the first roller 202 and the second roller 204, such as, but not limited to, AC or DC brushless motors, linear motors, servo motors, stepper motors, pneumatic actuators, hydraulic actuators, etc.

[0100] In an embodiment, the recoating assembly 200 includes one or more sensors mechanically coupled to roller supports 210, 212, 216 and / or 218, the one or more sensors being configured to output signals indicating forces occurring on the roller supports 210, 212, 216 and / or 218 via the first roller 202 and / or the second roller 204.

[0101] For example, refer to Figures 7A to 7C In one embodiment, strain gauge 240A is mechanically coupled to the first roller support 210. In another embodiment, strain gauge 240A is a first strain gauge 240A, and a second strain gauge 240B is mechanically coupled to the first roller support 210. Although strain gauges 240A and 240B are mentioned herein as being mechanically coupled to the first roller support 210, it should be understood that one or more strain gauges may be coupled to any one or all of the first roller support 210, the second roller support 212, the third roller support 216, and the fourth roller support 218.

[0102] In an embodiment, roller supports 210, 212, 216, and / or 218 define one or more flexural portions 214, to which strain gauges 240A and 240B are coupled. Strain gauges 240A and 240B are configured to detect elastic deformation of the flexural portions 214, which is generally related to forces acting on the roller supports 210, 212, 216, and / or 218. In the depicted embodiment, the flexural portion 214 is the wall of a cavity extending through the roller supports 210, 212, 216, and / or 218; however, it should be understood that the flexural portion 214 may include any suitable portion of the roller supports 210, 212, 216, and / or 218 that elastically deforms such that the strain of the flexural portion 214 can be determined.

[0103] In the embodiment, strain gauges 240A and 240B are oriented to measure strain. For example, in Figure 7A and Figure 7B In the illustrated embodiment, strain gauges 240A and 240B are oriented in the vertical direction (i.e., in the depicted Z direction, and transverse to the first axis of rotation 226) and measure strain on a resultant vector at an angle between the horizontal (X-axis) and vertical (Z-axis) directions. By measuring the strain in the direction of the resultant vector, the normal force, i.e., the force acting on the roller supports 210, 212, 216, and / or 218 in a direction transverse to the coating direction, can be determined. For example, when the recoating assembly 200 moves the build material 31 on the build area 124 to cover the build material 31 (FIG. 2) and / or the cured adhesive 50 with a layer of build material 31, the force normal to the X and Z directions can be transmitted through the build material 31 distributed by the recoating assembly 200. Figure 2A ) and / or by cured adhesive 50 ( Figure 2A The adhesive 50 is applied to roller supports 210, 212, 216, and / or 218. One or more parameters of the operation of the recoating assembly 200 can be changed to reduce the normal force acting on roller supports 210, 212, 216, and / or 218 to maintain the cured adhesive 50 positioned below the build material 31. Figure 2C The structural integrity of the adhesive building material 31, as described in more detail below.

[0104] refer to Figure 8In some embodiments, one or both of strain gauges 240A and 240B are oriented in the horizontal direction (i.e., in the depicted X direction, and transverse to the first axis of rotation 226) and can measure strain on the resultant vector at an angle between the horizontal (X-axis) and vertical (Z-axis) directions. In some embodiments, strain gauges 240A and 240B may be oriented in the horizontal direction on the first roller support 210 and the second roller support 212, while strain gauges 240A and 240B may be oriented in the vertical direction on the third roller support 216 and the fourth roller support 218, as shown below. Figures 7A to 7B As depicted in the diagram. By measuring the strain in the horizontal direction (i.e., in the depicted X direction), the shear force, i.e., the force acting on the roller supports 210, 212, 216, and / or 218 in the direction corresponding to the coating direction, can be determined. For example, when the recoating assembly 200 moves to the build area 124 to cover the previous layer of build material 31 bonded by the cured adhesive 50 and / or to cover the build material 31 with another layer of build material 31, the shear force can be transmitted through the build material 31 distributed by the recoating assembly 200 ( Figure 2A ) and / or by means of cured adhesive 50 ( Figure 2A The adhesive building material 31 is applied to the roller supports 210, 212, 216 and / or 218. One or more parameters of the operation of the recoating assembly 200 can be changed to reduce the shear forces acting on the roller supports 210, 212, 216 and / or 218, thereby maintaining the bonded adhesive 50. Figure 2A The structural integrity of the adhesive building material 31, as described in more detail herein. As described in more detail herein, the determined force can also be applied in the open-loop (i.e., feedforward) control and / or closed-loop (i.e., feedback) control of the recoating assembly 200. For example, in an embodiment, the determined force can be compared to a lookup table of desired forces, and one or more parameters of the operation of the recoating assembly 200 can be changed based on the comparison result of the determined force and the desired force. In an embodiment, the forces acting on the roller supports 210, 212, 216 and / or 218 can depend on any of several factors, including but not limited to, the building material 31 ( Figure 2A The layer thickness is 200 ( ) and the recoating component is 200 ( Figure 2A The traverse speed of the first roller 202 and / or the second roller 204 ( Figure 6C The direction and rotation speed of the material, constructing material 31 ( Figure 2A Type / composition of ) and building material 31 Figure 2A Particle size, adhesive 50 ( Figure 2A Type / Composition of Adhesive Material 50 ( Figure 2AThe volume (or saturation) of the adhesive, whether and how the adhesive is partially or fully cured in situ, the geometry of the part being constructed, etc.

[0105] In some embodiments, information relating to the current and / or previous layer of the object being constructed can be used to generate the desired force or stress curve that the repainting component 200 will experience as it traverses the construction region 124. In some embodiments, the geometry of the current layer of the object being constructed or the geometry of the previous layer being constructed can be used to determine the desired pressure or force distribution (e.g., the shear force expected to be experienced when the recoating assembly 200 traverses the build area 124 to distribute the material for the current layer, the normal force expected to be experienced when the recoating assembly 200 traverses the build area 124 to distribute the material for the current layer, and / or any other type of force expected to be experienced when the recoating assembly 200 traverses the build area 124 to distribute the material for the current layer). Output signals from one or more sensors coupled to the roller support (e.g., one or more strain gauges and / or one or more load sensors) can be used to calculate the measured force or pressure when the recoating assembly 200 traverses the build area 124 to distribute the material for the current layer. A comparison between the desired pressure or measured force distribution and the measured force or pressure can be made, and actions can be taken in response to the comparison results. In some embodiments, a lookup table containing desired force or pressure information may be previously generated, such as based on calibrated force measurements produced under various conditions (e.g., dimensions of the build area coated with adhesive, recoating cross-country speed, recoating roller rotation speed, layer thickness, recoating roller geometry, etc.). For example, in some embodiments, a defect in the print recoating process can be determined when the desired pressure or force deviates from the measured pressure or force during the spreading of material for the current layer by the recoating assembly 200. The degree of force deviation can be used to determine the type of defect (e.g., powder defect, recoating roller defect, insufficient adhesive curing, spraying defect, etc.). When it is determined that a deviation exceeding a given threshold has occurred, corrective actions can be taken, such as adjusting the recoating cross-country speed for the current layer, adjusting the roller rotation speed for the current layer, adjusting the recoating cross-country speed for one or more subsequent layers, adjusting the roller rotation speed for one or more subsequent layers, adjusting the height of one or more rollers for the current layer and / or for one or more subsequent layers, etc. Such measurement, comparison, and control actions can be implemented by an electronic control unit 300 executing one or more instructions stored in its memory component.

[0106] In some embodiments, one or more sensors mechanically coupled to roller supports 210, 212, 216 and / or 218 may include load sensors.

[0107] For example, refer to Figures 9A to 9DIn one embodiment, the load sensor 242 is mechanically coupled to the first roller support 210 and configured to measure the force in the vertical direction (i.e., in the depicted Z direction, and transverse to the first axis of rotation 226). Figure 9C As shown in the figure, in some embodiments, the set screw 246 may engage the load sensor 242 to calibrate the load sensor 242, for example, by applying a known amount of force to the load sensor 242.

[0108] refer to Figure 10 In some embodiments, the first roller support 210 may include both a load sensor 242 and strain gauges 240A and 240B. Although in Figure 10 In the embodiments depicted, strain gauges 240A and 240B are oriented in the horizontal direction; however, it should be understood that one or both of strain gauges 240A and 240B may be oriented in the vertical direction.

[0109] In some embodiments, the accelerometer 244 is coupled to the first roller support 210. Although in Figure 10 In the embodiments depicted, load sensor 242, strain gauges 240A, 240B, and accelerometer 244 are coupled to the first roller support 210. However, it should be understood that in some embodiments, only accelerometer 244 may be mechanically coupled to the first roller support 210. In some embodiments, accelerometer 244 is coupled to the first roller support 210 together with any combination of load sensor 242, strain gauge 240A, and / or strain gauge 240B. Moreover, accelerometer 244 may be coupled to any one of roller supports 210, 212, 216, and / or 218.

[0110] In some embodiments, a roller support temperature sensor 247 is coupled to a first roller support 210. The roller support temperature sensor 247 is operable to detect the temperature of the roller support 210 and can be used to calibrate and / or compensate for load sensor readings from a load sensor 242. Although in Figure 10 In the embodiments depicted, load sensor 242, strain gauges 240A, 240B, accelerometer 244, and roller support temperature sensor 247 are coupled to the first roller support 210. However, it should be understood that in some embodiments, only roller support temperature sensor 247 may be mechanically coupled to the first roller support 210. In some embodiments, roller support temperature sensor 247 is coupled to the first roller support 210 together with any combination of load sensor 242, strain gauge 240A, strain gauge 240B, and / or accelerometer 244. Moreover, roller support temperature sensor 247 may be coupled to any one of roller supports 210, 212, 216, and / or 218.

[0111] refer to Figure 11AIn some embodiments, the recoating assembly 200 generally includes a front energy source 260, which is coupled to the base member 250 and positioned in front of the front roller 202 (i.e., in the painted +X direction). Figure 11A In the illustrated embodiment, the recoating assembly 200 further includes a rear energy source 262, which is coupled to the base member 250 and positioned behind the rear roller 204 (i.e., in the illustrated -X direction). A front energy source 260 emits energy generally in front of the front roller 202, and a rear energy source 262 emits energy behind the rear roller 204. In embodiments, the front and rear energy sources 260 and 262 can generally emit electromagnetic radiation, such as infrared radiation, ultraviolet radiation, etc. In some embodiments, the front and rear energy sources 260 and 262 can emit energy that can be used to heat the building material 31 (…). Figure 2A ) and / or the adhesive material 50 on the cured building material 31 Figure 2A (as described in more detail in the text). Although in Figure 11A In the embodiments depicted, the front energy source 260 is positioned in front of the front roller 202 and the rear energy source 262 is positioned behind the rear roller 204; however, it should be understood that this is merely an example. For instance, in some embodiments, both the front energy source 260 and the rear energy source 262 may be positioned in front of the front roller 202, such as... Figure 6A As shown, or, the front energy source 260 and the rear energy source 262 can both be positioned behind the front roller 202 and the rear roller 204. By including multiple energy sources (e.g., front energy source 260 and rear energy source 262), energy can be applied to the building material 31 over a relatively longer period of time compared to applying energy via a single energy source. Figure 1 A). In this way, over-curing of the building material 31 bonded by the cured adhesive 50 can be minimized. Although in Figure 11A In the embodiments depicted herein, a front energy source 262 and a rear energy source 262 are shown; however, it should be understood that the embodiments described herein may include any suitable number of energy sources positioned in front of and behind the front roller 202 and the rear roller 204 in any suitable manner. See also Figures 11B to 11D In some embodiments, the recoating assembly 200 includes one or more rigid stops 410 coupled to the base member 250. Although in Figure 11C and Figure 11D The cross-sectional view depicted shows a single hard stop 410; however, it should be understood that each hard stop 410 can be identical. Additionally, although in Figure 11B In the embodiments depicted, the recoating assembly 200 includes two hard stops 410; however, it should be understood that the recoating assembly 200 may include a single hard stop 410 or any suitable number of hard stops 410.

[0112] The hard stop 410 can help limit the movement of the first roller 202 and / or the second roller 204 about the depicted Y-axis, for example, as a result of the actuation of the roller vertical actuator 252. See, for example, particularly... Figure 11A , Figure 11C and Figure 21 In some embodiments, a roller vertical actuator 252 is coupled to a pivot portion 249 of a base member 250, the pivot portion 249 being movable relative to a stationary portion 251 of the base member 250 about a depicted Y-axis. A first roller 202 and a second roller 204 may be coupled to the pivot portion 249 such that movement of the pivot portion 249 about the Y-axis causes movement of the first roller 202 and / or the second roller 204 about the depicted Y-axis.

[0113] In one embodiment, the rigid stop 410 includes a connecting portion 414 connected to a pivot portion 249 of the base member 250 and a column portion 412 movably engaged with a stationary portion 251 of the base member 250. For example, the column portion 412 of the rigid stop 410 is movable relative to the stationary portion 251 in a vertical direction (e.g., in the depicted Z direction). The movement of the column portion 412 of the rigid stop 410 in the vertical direction (e.g., in the depicted Z direction) can be restricted. For example, a nut 420 can be adjustably engaged with the column portion 412 and can restrict the movement of the column portion 412 relative to the stationary portion 251 of the base member 250. Because the connecting portion 414 of the rigid stop 410 is connected to the pivot portion 249 of the base member 250, restricting the movement of the column portion 412 of the rigid stop 410 relative to the stationary portion 251 restricts the movement of the pivot portion 249 relative to the stationary portion 251 in the vertical direction (e.g., in the depicted Z direction). In some embodiments, the nut 420 is adjustable on the column portion 412 in the depicted Z direction. By moving the nut 420 along the column portion 412 in the Z direction, the degree of freedom of movement of the pivot portion 249 of the base member 250 (therefore, the first roller 202 and / or the second roller 204) relative to the stationary portion 251 of the base member 250 can be adjusted. By means of the rigid stop 410, via actuation of the roller vertical actuator 250, the movement of the pivot portion 249 of the base member 250 (therefore, the first roller 202 and / or the second roller 204) can be precisely modulated as needed. Although in Figure 11C and Figure 11D In the embodiment depicted, the hard stop 410 includes a nut 420 that restricts movement of the hard stop 410; however, it should be understood that this is merely an example. For instance, in some embodiments, movement of the hard stop 410 can be restricted by a manual micrometer, one or more motors, etc. For example, as... Figure 16BAs best illustrated, in some embodiments, the recoating assembly may include a plurality of hard stops 410 that restrict movement of the first roller 202 and the second roller about the painted Y-axis. The hard stops 410 may include a micrometer for moving the position of the hard stops 410. In some embodiments, the hard stops 410 may further include a load sensor for detecting the position of the hard stops 410.

[0114] In some embodiments, the post portion 412 of the rigid stop 410 extends through the orifice 253, which extends through the stationary portion 251 of the base member 250. In some embodiments, the recoating assembly 200 includes a dust cover 430 that at least partially seals the orifice 253 and / or at least a portion of the rigid stop 410. For example, in Figure 11C and Figure 11D In the embodiment depicted, the dust cover 430 includes an upper portion 432 and a lower portion 434, the upper portion 432 at least partially covering the upper opening of the orifice 253 and the post portion 414 of the rigid stop 410, and the lower portion 434 at least partially covering the lower opening of the orifice 253. The dust cover 430 may further include a lower biasing member 436 biasing the lower portion 434 of the dust cover 430 to engage with the orifice 253. The dust cover 430 may further include an upper biasing member 438 biasing the upper portion 432 of the dust cover 430 to engage with the orifice 253. By at least partially surrounding the orifice 253, the dust cover 430 can help prevent the construction material 31 ( Figure 1 The material enters through orifice 253 and interferes with the movement of the post portion 412 of the hard stop 410 through orifice 253. Further, in an embodiment, the lower bias member 436 and / or the upper bias member 438 can at least partially counteract the tension caused by the connection between the first rotary actuator 206 and the first roller 202 and / or between the second rotary actuator 208 and the second roller 204. For example, as... Figure 11B As shown, a first rotary actuator 206 can be coupled to a first roller 202 via a belt. Similarly, a second rotary actuator 208 can be coupled to a second roller 204 via a belt. Tension in the belt can cause the first roller 202 and / or the second roller 204 to move in the depicted Z direction, as shown. This movement can be resisted by a lower bias member 436 and / or an upper bias member 438, thereby stabilizing the position of the first roller 202 and / or the second roller 204 in the depicted Z direction.

[0115] refer to Figure 11EA lower perspective view of a recoating assembly 200 is schematically depicted. In some embodiments, the recoating assembly 200 includes a powder guide 450 pivotally connected to a substrate member 250 of the recoating assembly 200 at a pivot point 452. As depicted, the powder guide 450 is capable of pivoting about a Y-axis relative to the substrate member 250. By pivoting about a Y-axis relative to the substrate member 250, the powder guide 450 can maintain contact with the build platform 20 as the rollers 202, 204 move in the depicted Z-direction. Figure 1 ) and / or supply platform 30 ( Figure 1 ) contact. Powder guide 450 can help confine the build material 31 ( Figure 1 ) Flow away from the repainting component 200 in the Y direction.

[0116] refer to Figure 11A and Figure 12 In some embodiments, the front energy source 260 and the rear energy source 262 are each at least partially located within the energy source housing 264. In some embodiments, the energy source housing 264 may focus the energy emitted by the front energy source 260 and the rear energy source 262, and may include reflective internal surfaces, etc.

[0117] In some embodiments, the recoating assembly 200 includes one or more housing temperature sensors 266. Figure 12 In the embodiments depicted, the recoating assembly 200 includes a housing temperature sensor 266 coupled to the energy source housing 264 of the front energy source 260 and a housing temperature sensor 266 coupled to the energy source housing 264 of the front energy source 262. In embodiments, the housing temperature sensor 266 is configured to detect the temperature of the respective front energy source 260 and rear energy source 262 and / or energy source housing 264. The energy emitted by the front energy source 260 and rear energy source 262 can be controlled, at least in part, based on the detected temperatures of the front energy source 260 and rear energy source 262 and / or energy source housing 264, thereby preventing damage to the front energy source 260 and rear energy source 262 and / or energy source housing 264, and / or ensuring that appropriate energy is applied to the building material 31.

[0118] In some embodiments, the recoating assembly 200 includes one or more housing engagement members 257 positioned at an outer end of the recoating assembly 200 and engaging with the housing of the additive manufacturing system 100. The housing engagement members 257 are generally configured to engage sides of the additive manufacturing system 100 and “plow” or “scrape” build-up material 31 from sides of the additive manufacturing system 100. In embodiments, the housing engagement members 257 may include any suitable structure, such as a brush, scraper, etc.

[0119] refer to Figure 12A schematic side view of the recoating assembly 200 is depicted. In an embodiment, the front roller 202 has a front roller diameter d1, and the rear roller 204 has a rear roller diameter d2. In some embodiments, the front roller diameter d1 is different from the rear roller diameter d2. For example, in some embodiments, the front roller diameter d1 is smaller than the rear roller diameter d2. In an embodiment, the front roller diameter d1 is between 20 mm and 25 mm, including the endpoints. In some embodiments, the front roller diameter d1 is between 10 mm and 40 mm, including the endpoints. In some embodiments, the front roller diameter d1 is less than about 22.23 mm. As described in more detail herein, a relatively small diameter can help the front roller 202 fluidize the build material 31 to distribute the build material 31. In an embodiment, the rear roller diameter d2 is between 35 mm and 40 mm, including the endpoints. In an embodiment, the rear roller diameter d2 is between 20 mm and 60 mm, including the endpoints. In some embodiments, the rear roller diameter d2 is greater than about 38.1 mm. As described in more detail herein, a relatively large diameter can help the rear roller 204 compact the build material 31.

[0120] In some embodiments, the recoating assembly 200 includes a powder bonding member 255, which is coupled to the substrate member 250. Figure 11A And it is positioned in front of the front roller 202. In an embodiment, the powder bonding member 255 is positioned at an assessed height in the vertical direction (i.e., in the depicted Z direction), which is within the roller window Rw defined by the front roller 202. The powder bonding member 255 can be a "scraper" generally used to plow and clean the build material 31 in front of the front roller 202, thereby minimizing the height of the build material 31 contacted by the front roller 202. Although in the depicted embodiment, the recoating assembly 200 includes the powder bonding member 255 as well as the front roller 202 and the rear roller 204, it should be understood that in some embodiments, the recoating assembly 200 may only include the powder bonding member 255 to spread the build material 31. Although in Figure 12 In the embodiments depicted herein, the powder bonding member 255 is positioned in front of the front roller 202; however, the embodiments described herein may include one or more powder bonding members positioned in front of the front roller 202 and / or behind the rear roller 204.

[0121] In some embodiments, the recoating assembly 200 includes a plurality of front rollers 202 and / or a plurality of rear rollers 204.

[0122] For example, refer to Figure 13 A top view schematically depicting one configuration of front rollers 202A, 202B and rear rollers 204A, 204B. Figure 13In the embodiment depicted, the recoating assembly 200 includes a first front roller 202A and a second front roller 202B, the second front roller 202B being spaced apart from the first front roller 202A in a lateral direction (i.e., in the depicted Y direction). Figure 13 In the embodiment depicted, the recoating assembly 200 further includes a first rear roller 204A and a second rear roller 204B, the second rear roller 204B being spaced apart from the first rear roller 202A in the lateral direction (i.e., in the depicted Y direction). Although Figure 13 The embodiments depicted include two front rollers 202A, 202B and two rear rollers 204A, 204B. However, it should be understood that the recoating assembly 200 may include any suitable number of front rollers spaced apart from each other in the lateral direction (i.e., in the depicted Y direction) and any suitable number of rear rollers spaced apart from each other in the lateral direction. In some embodiments, the recoating assembly 200 may include two front rollers 202A, 202B and a single rear roller, or two rear rollers 204A, 204B and a single front roller. By including a plurality of front rollers 202A, 202B aligned with each other in the lateral direction (i.e., in the depicted Y direction), and / or by including a plurality of rear rollers 204A, 204B aligned with each other in the lateral direction, the recoating assembly 200 can extend a greater distance in the lateral direction compared to a recoating assembly including a single front roller and a single rear roller. As an example, and without being bound by theory, the longer the roller extends in the lateral direction (i.e., in the depicted Y direction), the more susceptible the roller is to elastic and / or inelastic deformation due to forces acting on it. This effectively limits the width of the recoating assembly, which includes a single front roller and a single rear roller, thereby limiting the size of the object that can be constructed by the additive manufacturing system 100. However, by including a plurality of front rollers 202A, 202B aligned with each other in the lateral direction (i.e., in the depicted Y direction), and / or by including a plurality of rear rollers 204A, 204B aligned with each other in the lateral direction, the recoating assembly 200 can extend a greater distance in the lateral direction.

[0123] refer to Figure 14 In some embodiments, the front rollers 202A, 202B overlap each other in the lateral direction (i.e., in the depicted Y direction). In embodiments where the recoating assembly 200 includes two rear rollers 204A, 204B, the two rear rollers may similarly overlap each other in the lateral direction (i.e., in the depicted Y direction). By making the front rollers 202A, 202B and / or the rear rollers 204A, 204B overlap in the lateral direction (i.e., in the depicted Y direction), the front rollers 202A, 202B and / or the rear rollers 204A, 204B can prevent the building material 31 ( Figure 12 It passes between adjacent front rollers 202A, 202B and / or adjacent rear rollers 204A, 204B.

[0124] refer to Figure 15 In some embodiments, the rollers are positioned to extend across the gap defined by adjacent rollers. For example, in Figure 15 In the illustrated embodiment, the recoating assembly 200 includes three front rollers 202A, 202B, and 202C, wherein adjacent front rollers 202A and 202B define a gap G1 positioned in the lateral direction (i.e., in the depicted Y direction) between rollers 202A and 202B, and adjacent front rollers 202B and 202C define a gap G2 positioned in the lateral direction between rollers 202B and 202C. The recoating assembly 200 includes a rear roller 204A extending between adjacent front rollers 202A and 202B and a rear roller 204B extending between adjacent front rollers 202B and 202C. Specifically, the rear roller 204A extends across the gap G1 between adjacent front rollers 202A and 202B, and the rear roller 204B extends across the gap G2 between adjacent front rollers 202B and 202C. By extending across gaps G1 and G2, the rear rollers 204A and 204B can engage the building material 31 passing through gaps G1 and G2. Figure 12 ).

[0125] refer to Figure 16A In some embodiments, the recoating assembly 200 includes a cleaning member 270. In embodiments, the cleaning member 270 is capable of selectively engaging at least one roller. For example, in Figure 16A In the embodiment depicted, the cleaning member 270 is positioned between the first roller 202 and the second roller 204, and engages with both the first roller 202 and the second roller 204. Figure 16A In the embodiment depicted, the cleaning member 270 engages the first roller 202 and the second roller 204 generally along a length assessed in the lateral direction (i.e., in the depicted Y direction) and substantially removes the building material 31 that may remain attached to the first roller 202 and the second roller 204 during rotation. Figure 12 ) and / or cured adhesive 50 ( Figure 12 In some embodiments, the cleaning member 270 is a cleaning roller including grooves 272 or a brush, configured to rotate while engaging with the first roller 202 and the second roller 204. In some embodiments, the cleaning member 270 may include a scraper, etc., which removes the building material 31 from the first roller 202 and the second roller 204. Figure 12 Although in Figure 16A In the embodiments depicted, the cleaning member 270 engages synchronously with the first roller 202 and the second roller 204; however, it should be understood that in some embodiments, the cleaning member 270 may engage only with either the first roller 202 or the second roller 204. Additionally, although... Figure 16AThe embodiments depicted herein depict a single cleaning component 270; however, it should be understood that in embodiments, the repainting component 200 may include a plurality of cleaning components 270.

[0126] In some embodiments, the position of the cleaning member 270 may be adjusted relative to the first roller 202 and / or the second roller 204. For example, refer to Figure 16B , Figure 16C and Figure 16D In some embodiments, the recoating assembly 200 includes a cleaning position adjustment assembly 500. In some embodiments, the cleaning position adjustment assembly 500 includes a first rotating member 510 and a second rotating member 520. Figure 16D As best shown in some embodiments, the first rotating member 510 includes a first notched flange 512 and a first eccentric tube 514. The second rotating member 520 includes a second notched flange 522 and a second eccentric tube 524. In embodiments, the first eccentric tube 514 can be inserted into the second eccentric tube 524, such as... Figure 16C As shown in the figure. The cleaning position adjustment assembly 500 may further include a bearing 530 that can be inserted into the first eccentric tube 514, and the cleaning member 270 engages with the bearing 530.

[0127] By rotating the first rotating member 2510 and / or the second rotating member 520 relative to each other, the position of the cleaning member 270 relative to the base member 250 can be adjusted, and the first roller 202 and the second roller 204 can be adjusted accordingly. For example, the position of the second rotating member 520 relative to the base member 250 can be substantially fixed. When the first rotating member 510 and the second rotating member 520 rotate relative to each other, the eccentricity of the first eccentric tube 514 and the second eccentric tube 524 causes the cleaning member 270 to move relative to the base member 250 (and correspondingly relative to the first roller 202 and the second roller 204). In this way, a user (such as a technician) can adjust the position of the cleaning member 270 relative to the first roller 202 and the second roller 204. In some embodiments, the cleaning position adjustment assembly 500 further includes one or more pins 540 that can be inserted into the base member 250 through notches in the first notched flange 512 and the second notched flange 522. The one or more pins 540 restrict the rotational movement of the first rotating member 510 and the second rotating member 520 relative to each other and relative to the base member 250. Once the cleaning member 270 is positioned as needed, one or more pins 540 can be positioned into the base member 250 through the notches of the first notched flange 512 and the second notched flange 522, for example by a technician. In some embodiments, the first rotating member 510 and / or the second rotating member 520 can be rotated and / or held in place relative to each other by actuators, etc.

[0128] refer to Figures 17A to 17C The diagram schematically depicts a top view and a side view of a cleaning member 270 engaged with the first roller 202 and the second roller 204. (Reference) Figure 17A In some embodiments, such as those where the first roller 202 and the second roller 204 are offset from each other in the lateral direction (i.e., in the depicted Y direction), the cleaning member 270 may extend along the lateral length of both the first roller 202 and the second roller 204. Figure 17B As shown in the embodiment where the first roller 202 and the second roller 204 are aligned with each other, the cleaning member 270 can similarly extend along the length of both the first roller 202 and the second roller 204 in the lateral direction (i.e., in the depicted Y direction). Figure 17C In the embodiment depicted, the cleaning member 270 is positioned generally vertically (i.e., in the depicted Z direction) on the first roller 202 and the second roller 204.

[0129] refer to Figure 11A , Figure 18A , Figure 18B and Figure 22 In some embodiments, the recoating assembly 200 is in fluid communication with the vacuum section 290. Specifically, in embodiments, the vacuum section 290 is in fluid communication with at least a portion of the substrate member 250 of the recoating assembly 200. The vacuum section 290 is generally operable to carry the airborne construction material 31 ( Figure 12 Extracted from recoating component 200, and / or, controlled atomization of build material 31 in additive manufacturing system 100 Figure 2A The flow within rollers 202 and 204. Specifically, this applies to the flow within rollers 202 and 204. Figure 19 Fluidized construction materials 31 Figure 17C During this process, some building material 31 will become airborne and, unless controlled, could contaminate components of the additive manufacturing system 100. In an embodiment, the vacuum unit 290 may include any suitable means, such as a pump, for applying negative and / or positive pressure to the recoating assembly 200. Figure 18A As depicted, the base member 250 generally includes a secondary containing shell 278. In some embodiments, the primary containing shell 276 and / or the secondary containing shell 278 may include one or more adjustable openings 279, which are adjustable to open and close to selectively restrict the flow of air and / or building materials through the primary containing shell 276 and / or the secondary containing shell 278. For example, as Figure 11A and Figure 23As shown, the primary containment housing includes a first adjustable opening 279 and a second adjustable opening 279'. The recoating assembly 200 may further include a first movable cap 269 that selectively covers the first adjustable opening 279. For example, the first movable cap 269 may be movable along the depicted Z direction to selectively widen or narrow (evaluated in the depicted Z direction) the first adjustable opening 279. Similarly, the recoating assembly 200 may include a second movable cap 269' that selectively covers the second adjustable opening 279'. For example, the second movable cap 269' may be movable in the depicted Z direction to selectively widen or narrow (evaluated in the depicted Z direction) the second adjustable opening 279' independently of the first adjustable opening 279. By widening or narrowing the first adjustable opening 279 and / or the second adjustable opening 279', the airflow into the primary containment housing 276 can be modulated as desired to guide the flow of the building material 31 in the air. Figure 18B The base member 250 with the secondary containing shell 278 removed is shown, and the primary containing shell 276 of the base member 250 is depicted.

[0130] Unrestricted by theory, the airborne build material 31 may include particles smaller than the average particle size of the un-airborne build material 31. Thus, by extracting the smaller-sized airborne build material 31 from the recoating assembly 200, it is supplied to the reservoir 134. Figure 2A ) and / or construct region 124 ( Figure 2A , Figure 2B The average particle size of the build material 31 in the recoating assembly 200 can be increased. Therefore, in some embodiments, build material 31 comprising smaller particles (such as build material 31 drawn from the recoating assembly 200) can be periodically reintroduced into the supply reservoir 134. Figure 2A ) and / or construct material hopper 360 ( Figure 2A To maintain a relatively consistent particle size in the building material 31.

[0131] refer to Figure 19 A cross-sectional view of the base member 250 is depicted. In an embodiment, a primary containing housing 276 at least partially encloses the powder spreading members (e.g., the first roller 202 and the second roller 204, and / or the powder bonding member 255). Figure 12The secondary containing shell 278 is spaced apart from the primary containing shell 276 and at least partially seals the primary containing shell 276. The primary containing shell 276 and the secondary containing shell 278 generally define an intermediate cavity 277 disposed between the primary containing shell 276 and the secondary containing shell 278. In an embodiment, a vacuum section 290 is in fluid communication with the intermediate cavity 277 and is operable to evacuate building material 31 from the intermediate cavity 277. In some embodiments, the intermediate cavity 277 is a front intermediate cavity 277, and the secondary containing shell 278 and the primary containing shell 276 define a rear intermediate cavity 283 separated from the front intermediate cavity 277 by a partition 281. By separating the front intermediate cavity 277 and the rear intermediate cavity 283, different vacuum pressures can be applied to the front intermediate cavity 277 and the rear intermediate cavity 283. For example, the rear intermediate cavity 283 may pass through the generally settled building material 31, so it may be desirable to apply a small vacuum pressure at the rear intermediate cavity 283 to avoid disturbing the settled building material 31.

[0132] In some embodiments, the recoating assembly 200 further includes an agitation device 284 coupled to the substrate member 250. The agitation device 284 is operable to vibrate components of the recoating assembly 200, such as the substrate member 250, the first roller 202, and / or the second roller 204, to remove build-up material 31 that may be attached to the substrate member 250 and / or the first roller 202 and the second roller 204. Figure 12 ). refer to Figure 20 and Figure 21 In some embodiments, the substrate member 250 may consist only of a primary containing shell 276 that at least partially surrounds the powder spreading member (e.g., the first roller 202 and / or the second roller 204). In these embodiments, the vacuum section 290 is in fluid communication with the primary containing shell 276.

[0133] refer to Figure 22 A schematic cross-sectional view of the base member 250 is depicted. (e.g.) Figure 22 As shown, the vacuum section 290 is in fluid communication with the primary containing shell 276 and is generally operated to evacuate the building material 31 from the air. Figure 12 In some embodiments, the recoating assembly 200 includes a diffuser plate 280 positioned between a vacuum section 290 and a powder spreading member (e.g., a first roller 202 and / or a second roller 204). The diffuser plate 280 generally includes a plurality of orifices 282 extending therethrough. The diffuser plate 280 generally helps to distribute the negative pressure applied to the primary containment housing 276 by the vacuum section 290.

[0134] refer to Figure 23In some embodiments, the vacuum section 290 is operable to draw airborne build material 31 from the recoating assembly 200, and further operable to guide the collected build material 31 below the recoating assembly 200 in a vertical direction (i.e., in the depicted Z direction). Figure 23 In the embodiment depicted, a vacuum section 290 is positioned within a primary containment housing 276 and between a first roller 202 and a second roller 204. The vacuum section 290 is generally used to draw in and collect airborne build material 31, which is then deposited beneath the recoating assembly 200. Figure 23 In the embodiment depicted, a vacuum section 290 is positioned between a first roller 202 and a second roller 204, and the vacuum section 290 deposits the collected build material 31 between the first roller 202 and the second roller 204. In some embodiments, the vacuum section 290 may be positioned outside the recoating assembly 200 and may redeposit the collected build material 31 at any suitable site below the recoating assembly 200.

[0135] refer to Figure 24 The diagram schematically depicts a control scheme for an additive manufacturing system 100. In one embodiment, strain gauges 240A, 240B, load sensor 242, and accelerometer 244 are communicatively connected to an electronic control unit 300. In another embodiment, a first rotary actuator 206 and a second rotary actuator 208, a recoating assembly lateral actuator 144, a recoating assembly vertical actuator 160, and a printhead actuator 154 are communicatively connected to the electronic control unit 300. The electronic control unit 300 is also communicatively connected to roller vertical actuators 252, 254, a front energy source 260 and a rear energy source 262, an agitator 284, one or more housing temperature sensors 266, and a vacuum unit 290. In some embodiments, temperature sensors 286 and distance sensors 288, as well as a roller support temperature sensor 247, are also communicatively connected to the electronic control unit 300, such as... Figure 24 As shown in the image.

[0136] In some embodiments, the electronic control unit 300 includes a current sensor 306. The current sensor 306 generally senses the current driving the recoating assembly lateral actuator 144, the first rotary actuator 206, the second rotary actuator 208, the vertical actuator 160, and / or the printhead actuator 154. In embodiments where the recoating assembly lateral actuator 144, the first rotary actuator 206, the second rotary actuator 208, the vertical actuator 160, and / or the printhead actuator 154 are electrically actuated, the current sensor 306 senses the current driving the recoating assembly lateral actuator 144, the first rotary actuator 206, the second rotary actuator 208, the vertical actuator 160, and / or the printhead actuator 154. Although in Figure 24In the embodiments depicted, the current sensor 306 is portrayed as a component of the electronic control unit 300; however, it should be understood that the current sensor 306 may be a separate component communicatively connected to the electronic control unit 300. Furthermore, although in Figure 24 In the embodiments depicted, a single current sensor 306 is shown; however, it should be understood that the additive manufacturing system 100 may include any suitable number of current sensors 306 associated with the repainting assembly lateral actuator 144, the first rotary actuator 206, the second rotary actuator 208, the vertical actuator 160, and / or the printhead actuator 154.

[0137] In an embodiment, the electronic control unit 300 generally includes a processor 302 and a memory unit 304. The memory unit 304 may be configured as volatile and / or non-volatile memory, such as random access memory (including SRAM, DRAM, and / or other types of RAM), flash memory, secure digital storage (SD) memory cards, registers, optical discs (CDs), digital versatile optical discs (DVDs), Bernoulli-coded magnetic tape, and / or other types of non-transitory computer-readable media. The processor 302 may include any processing unit capable of operating to receive and execute instructions, such as those from the memory unit 304. In an embodiment, the electronic control unit 300 may store one or more operating parameters for operating the additive manufacturing system 100, as described in more detail herein.

[0138] The method for operating the repainting component 200 will now be described with reference to the accompanying drawings.

[0139] Common Reference Figure 24 and Figure 25 An example method of operating the recoating assembly 200 is schematically depicted. In the first step 2502, the electronic control unit 300 receives a first output signal from a first sensor. In this embodiment, the first sensor is mechanically coupled to a first roller support 210. Figure 6B And it contacts the first roller support 210, and may include any one of a first strain gauge 240A, a second strain gauge 240B, a load sensor 242, and / or an accelerometer 244. In an embodiment, the first sensor outputs a first output signal, the first output signal indicating an event occurring on the first roller 202 ( Figure 6B The first force on the first roller 202. In the second step 2504, the electronic control unit 300 determines the first roller 202 based on the first output signal of the first sensor. Figure 6B The first force on the additive manufacturing system 100. In step 2506, the electronic control unit 300 adjusts the additive manufacturing system 100 in response to the determined first force. Figure 2A At least one operating parameter of ).

[0140] As noted above, in this embodiment, the electronic control unit 300 may include one or more operating parameters for operating the additive manufacturing system 100. Figure 2A ). By responding to a determined action on the first roller 202 ( Figure 6B The electronic control unit 300 can actively adjust the operation of the additive manufacturing system 100 by using force on the additive manufacturing system 100 to adjust at least one operating parameter. As an example, in one embodiment, the additive manufacturing system 100 (… Figure 2A At least one parameter of the repainting component lateral actuator 144 relative to the build area 124 includes the repainting component lateral actuator 144. Figure 2A , Figure 2B ) Mobile repainting assembly 200 ( Figure 2A The speed of the recoating assembly 200 is determined to be below a configurable threshold once the force acting on the first roller 202 is determined to be below a configurable threshold. In this embodiment, the electronic control unit 300 can guide the recoating assembly lateral actuator 144 to increase the speed of the recoating assembly 200. Figure 2A ) relative to the constructed region 124 ( Figure 2A , Figure 2B The speed of movement. For example, the determination of a relatively low force or multiple forces acting on the first roller 202 can indicate that the recoating assembly 200 can be increased. Figure 2A The speed of movement is controlled without adversely affecting the first roller 202. In contrast, once the force acting on the first roller 202 is detected to exceed a configurable threshold, the electronic control unit 300 can guide the recoating assembly lateral actuator 144 to reduce the speed of movement of the recoating assembly 200. Figure 2A ) relative to the constructed region 124 ( Figure 2A , Figure 2B The speed of movement. For example, the determination of a relatively high force or multiple forces acting on the first roller 202 can indicate that the recoating assembly 200 should be reduced. Figure 2A The speed of movement is adjusted to reduce the force acting on the first roller 202.

[0141] In some embodiments, at least one parameter is in the vertical direction (e.g., in...). Figure 6B The first roller 202 (described in the Z direction) was evaluated. Figure 6B The height of the vertical actuator 160 relative to the build area 124 is determined to be below a configurable threshold once the force acting on the first roller 202 is determined to be below a configurable threshold. Figure 2A , Figure 2B Lowering the recoating assembly 200. For example, the determination of a relatively low force or multiple forces acting on the first roller 202 can indicate that the recoating assembly 200 can be lowered. Figure 2A ) Move to the height where it is located to engage the additional volume of building material 31 ( Figure 2AIn contrast, once the force acting on the first roller 202 exceeds a configurable threshold, the electronic control unit 300 can guide the vertical actuator 160 relative to the build area 124. Figure 2A , Figure 2B Raise the recoating assembly 200. For example, the determination of a relatively high force or multiple forces acting on the first roller 202 may indicate that the first roller 202 should be raised to engage the volume-reducing building material 31. Figure 2A ).

[0142] In some embodiments, at least one parameter of the additive manufacturing system 100 includes the printhead actuator 154 moving the printhead 150. Figure 2A The speed of the printhead actuator 154 is determined to be below a configurable threshold once the force acting on the first roller 202 is determined to be below a configurable threshold. In this embodiment, the electronic control unit 300 can instruct the printhead actuator 154 to increase the speed of the printhead actuator 154 relative to the build area 124. Figure 2A , Figure 2B ) Moving printhead 150 ( Figure 2A The speed of the first roller 202 can be determined by, for example, by the determination of a relatively low force or multiple forces acting on the first roller 202, which may indicate that the speed of the first roller 202 can be increased. Figure 2A ) relative to the constructed region 124 ( Figure 2A , Figure 2B The speed of movement can be increased, and similarly, the speed at which the printhead actuator 154 moves the printhead 150 can be increased, and / or, the speed of the adhesive 50 can be increased. Figure 1 A) volume. In contrast, once the force acting on the first roller 202 exceeds a configurable threshold, the electronic control unit 300 can guide the printhead actuator 154 to reduce the size of the printhead 150 ( Figure 2A ) relative to the constructed region 124 ( Figure 2A , Figure 2B The speed of movement. For example, the determination of a relatively high force or multiple forces acting on the first roller 202 can indicate that the speed of movement of the first roller 202 should be reduced. Figure 2A ) relative to the constructed region 124 ( Figure 2A , Figure 2B The speed of movement of the printhead 150 should be reduced, and similarly, the speed at which the printhead actuator 154 moves the printhead 150 should be reduced, and / or the speed of the adhesive 50 can be reduced. Figure 1 A) volume.

[0143] In some embodiments, the electronic control unit 300 is configured to adjust at least one operating parameter of the additive manufacturing system 100 based on a sensed current from a current sensor 306. For example, in one embodiment, the current sensor 306 may detect current from a first rotary actuator 206 and / or a second rotary actuator 208. Detection of current below a configurable threshold generally indicates a relatively low force acting on the first roller 202 and / or the second roller 204. In contrast, detection of current above the configurable threshold generally indicates a relatively high force acting on the first roller 202 and / or the second roller 204. In some embodiments, the current sensor 306 may sense the current of a lateral actuator 144 that drives the recoating assembly 200 to move relative to the build region 124. Similar to the first rotary actuator 206 and the second rotary actuator 208, detection of current below a configurable threshold generally indicates a relatively low force acting on the first roller 202 and / or the second roller 204. In contrast, the detection of current above the configurable threshold can generally indicate a relatively high force acting on the first roller 202 and / or the second roller 204.

[0144] refer to Figure 2A , Figure 2B , Figure 24 and Figure 26 This describes another method for adjusting at least one operating parameter of an additive manufacturing system 100. In a first step 2602, the method includes distributing a layer of build material 31 onto a build area using a recoating assembly 200. In a second step 2604, the method includes receiving a first output signal from a first sensor while distributing a layer of build material 31 onto a build area 124 using the recoating assembly 200. As described above, in an embodiment, the first sensor is mechanically coupled to a first roller holder 210. Figure 6B And it contacts the first roller support 210, and may include any one of a first strain gauge 240A, a load sensor 242, and / or an accelerometer 244. In an embodiment, the first sensor outputs a first output signal, the first output signal indicating an event occurring on the first roller 202 ( Figure 6B The first force on )

[0145] In step 2604, the method includes determining a first force on the first roller 202 based on a first output signal from a first sensor. In some embodiments, a lookup table containing desired force or pressure information may be previously generated, such as based on calibrated force measurements generated under various conditions (e.g., size of the build area coated with adhesive, recoating traverse speed, recoating roller rotation speed, recoating roller orientation, layer thickness, recoating roller geometry coating, etc.). In some embodiments, information relating to the current layer and / or previous layer of the object being built may be used to generate a desired force or pressure profile that will be experienced as the recoating assembly 200 traverses the build area 124. In some embodiments, the geometry of the current layer of the object being constructed or the geometry of the previous layer being constructed can be used to determine the desired pressure or force distribution (e.g., the shear force expected to be experienced when the recoating component 200 traverses the construction area 124 to distribute the material for the current layer, the normal force expected to be experienced when the recoating component 200 traverses the construction area 124 to distribute the material for the current layer, and / or any other type of force expected to be experienced when the recoating component 200 traverses the construction area 124 to distribute the material for the current layer), a comparison can be made between the desired pressure or measured force distribution and the measured force or pressure, and actions can be taken in response to the comparison result.

[0146] In step 2608, the method includes adjusting at least one operating parameter of the additive manufacturing system 100 in response to a determined first force. For example, in some embodiments, at least one operating parameter of the additive manufacturing system 100 is adjusted based on a comparison between a desired force on the first roller 202 and a first force on the first roller 202, and the first force on the first roller 202 is determined based on a first output signal from a first sensor. In embodiments, when it is determined that a deviation exceeding a given threshold has occurred, corrective actions can be taken, such as adjusting the recoating cross-flow speed for the current layer, adjusting the roller rotation speed for the current layer, adjusting the recoating cross-flow speed for one or more subsequent layers, adjusting the roller rotation speed for one or more subsequent layers, adjusting the height of one or more rollers for the current layer and / or for one or more subsequent layers, etc.

[0147] In some embodiments, when the desired pressure or force deviates from the measured pressure or force during the application of material to the current layer by the recoating assembly 200, a defect in the layer recoating process can be determined. The degree of force deviation can be used to determine the type of defect (e.g., powder defect, recoating roller defect, insufficient adhesive curing, spraying defect, etc.).

[0148] In an embodiment, each of steps 2602-2608 may be performed, for example, by an electronic control unit 300. As noted above, in an embodiment, the electronic control unit 300 may include one or more operating parameters for operating the additive manufacturing system 100. By responding to a determined action on the first roller 202 ( Figure 6B The electronic control unit 300 can actively adjust the operation of the additive manufacturing system 100 by applying force to adjust at least one operating parameter. As an example, in an embodiment, at least one parameter of the additive manufacturing system 100 includes the speed at which the recoating assembly 200 is moved relative to the build area 124 by the recoating assembly lateral actuator 144, as outlined above.

[0149] In some embodiments, at least one parameter is the rotational speed of the first rotary actuator 206. In an embodiment, once it is determined that the force acting on the first roller 202 is below a configurable threshold, the electronic control unit 300 can instruct the first rotary actuator 206 to reduce the speed at which it rotates the first roller 202. For example, the determination of a relatively low force or forces acting on the first roller 202 can indicate that the speed of the first rotary actuator 206 can be reduced while still being sufficient to fluidize the build material 31. In contrast, once it is detected that the force acting on the first roller 202 exceeds the configurable threshold, the electronic control unit 300 can instruct the first rotary actuator 206 to increase the speed at which it rotates the first roller 202. For example, the determination of a relatively high force or forces acting on the first roller 202 can indicate that the speed at which the first rotary actuator 206 rotates the first roller 202 is sufficient to fluidize the build material 31 as desired.

[0150] In some embodiments, at least one parameter is the target thickness of the subsequent layer build material 31 and / or the layer of build material 31 being distributed. In an embodiment, once it is determined that the force acting on the first roller 202 is below a configurable threshold, the electronic control unit 300 can guide the recoating assembly 200 to increase the target thickness of the subsequent layer build material 31, for example, by changing the height of the recoating assembly 200. For example, the determination of a relatively low force or multiple forces acting on the first roller 202 can indicate that the thickness of the layer of build material 31 distributed by the recoating assembly 200 can be increased. Conversely, once it is detected that the force acting on the first roller 202 exceeds the configurable threshold, the electronic control unit 300 can guide the recoating assembly 200 to decrease the target thickness of the subsequent layer build material 31, for example, by changing the height of the recoating assembly 200. For example, the determination of a relatively high force or multiple forces acting on the first roller 202 can indicate that the thickness of the layer of build material 31 distributed by the recoating assembly 200 should be decreased.

[0151] In some embodiments, Figure 26The method illustrated in the diagram further includes determining the type of defect. For example, in some embodiments, the type of defect can be determined based on a comparison between a desired force on the first roller 202 and a first force on the first roller 202. For example, a defect in the building material 31 can be associated with a specific amount of force applied to the first roller 202, while a defect in the first roller 202 can be associated with a different amount of force applied to the first roller 202. Therefore, the amount of force applied to the first roller 202 can be used to determine the type of defect within the additive manufacturing system 100.

[0152] In embodiments, at least one operating parameter of the additive manufacturing system 100 may be adjusted once or multiple times during the build cycle. For example, in embodiments, at least one operating parameter may be adjusted while a layer of build material 31 is being distributed by the recoating assembly 200. In some embodiments, at least one operating parameter of the additive manufacturing system 100 may be adjusted when the next layer of build material 31 is being distributed by the recoating assembly 200.

[0153] In some embodiments, wear parameters can be determined based on a defined first force. For example, as the first roller 202 wears, such as through repeated contact with the building material 31, the diameter of the first roller 202 can be substantially reduced. The reduced diameter of the first roller 202 as the building material 31 is distributed on the first roller 202 can generally result in a lower force on the first roller 202.

[0154] In some embodiments, wear on other components of the recoating assembly 200 can be determined based on a defined first force. For example, the first roller 202 may be coupled to the base member 250 via one or more bearings, etc. Figure 3 Additionally, as noted above, the first roller 202 can be connected to the first rotary actuator 206 via a belt, chain, etc. Figure 3 Wear on one or more bearings and / or belts, chains, etc., can generally result in an increased force on the first roller 202. In some embodiments, the increased force on the first roller 202 can be determined by a current sensor 306.

[0155] In some embodiments, Figure 26The method described further includes receiving a second output signal from a second sensor mechanically coupled to and in contact with the second roller support 212. In an embodiment, the second sensor may include any one of a first strain gauge 240A, a second strain gauge 240B, a load sensor 242, and / or an accelerometer 244. In an embodiment, the method further includes receiving the second output signal from the second sensor while a layer of build material 31 is distributed on the build region 124 using the recoating assembly 200, and determining a first force on the first roller 202 based on the first output signal from the first sensor and the second output signal from the second sensor.

[0156] In some embodiments, Figure 26 The method described further includes receiving a third output signal from a third sensor mechanically coupled to and in contact with the third roller support 216. In embodiments, the third sensor may include any one of a first strain gauge 240A, a second strain gauge 240B, a load sensor 242, and / or an accelerometer 244. In embodiments, the method further includes receiving the third output signal from the third sensor while distributing a layer of build material 31 on build area 124 using the recoating assembly 200, and determining a second force on the second roller 204 based on the third output signal from the third sensor. In some embodiments, the method further includes adjusting at least one operating parameter in response to the determined first force and the determined second force. Thus, at least one operating parameter can be adjusted based on the determined forces acting on both the first roller 202 and the second roller 204. For example, detection that the deceleration of the first roller 202 and / or the second roller 204 is higher than a configurable threshold may indicate a collision between the recoating assembly 200 and an object (such as a foreign object within the additive manufacturing system 100). By detecting a collision, the operation of the additive manufacturing system 100 can be stopped to prevent further damage to the additive manufacturing system 100, and / or, to provide the user with instructions that maintenance is necessary.

[0157] In some embodiments, Figure 26 The method described further includes determining a collision of the recoating assembly 200. For example, in some embodiments, the method further includes determining a roller collision event based on the output of at least one accelerometer 244, and adjusting at least one operating parameter when it is determined that a roller collision event has occurred.

[0158] refer to Figure 24 , Figure 27 and Figure 28The diagram schematically depicts a method for forming an object. In a first step 2702, the method includes moving a recoating assembly 200 along a coating direction over a supply reservoir 134, as indicated by arrow 40. The supply reservoir 134 contains build-up material 31 positioned within the supply reservoir 134, and the recoating assembly 200 includes a first roller 202 and a second roller 204 spaced apart from the first roller 202. As noted above, in some embodiments, the recoating assembly 200 may comprise only a single roller. In a second step 2704, the method includes rotating the first roller 202 of the recoating assembly 200 in a counter-rotational direction 60, such that the bottom of the first roller 202 moves in the coating direction 40. Figure 28 In the embodiment depicted, the reverse rotation direction 60 is shown as clockwise. In the third step 2706, the method includes contacting the build material 31 with the first roller 202 of the recoating assembly 200, thereby fluidizing at least a portion of the build material 31. In step 2708, the method includes irradiating the initial layer build material 31 positioned in a build region 124 spaced apart from the supply reservoir 134 using a front energy source 260. As noted above, irradiating the initial layer build material 31 can cause the build material 31 to adhere to the adhesive 50 positioned in the build region 124. After step 2708, in step 2710, the method includes moving the fluidized build material 31 from the supply reservoir 134 to the build region 124 using the first roller 202, thereby depositing a second layer build material 31 on the initial layer build material 31 within the build region 124. Following step 2710, in step 2712, the method includes irradiating the second layer of building material 31 within the building region 124 using a post-energy source 262. In some embodiments, steps 2708 to 2712 may occur within a predetermined period of time. For example, in some embodiments, steps 2708 to 2712 may be performed within a range of 5 seconds to 20 seconds.

[0159] While the method described above includes moving the recoating assembly 200 over the supply reservoir 134, it should be understood that in some embodiments, the supply reservoir 134 is not provided; instead, the build material 31 can be supplied via other means (such as a build material hopper 360). Figure 2B )) is placed on build area 124.

[0160] In one embodiment, the electronic control unit 300 can guide various components of the additive manufacturing system 100 to perform steps 2702 through 2712. In another embodiment, by irradiating the initial layer of build material 31, the front energy source 260 can be used to cure the adhesive 50 positioned on the build material 31 in the build region 124. By irradiating the second layer of build material 31, the rear energy source 262 can generally be used to preheat the build material 31 and / or further cure the adhesive 50.

[0161] By irradiating the build material 31 with a front energy source 260 separate from the rear energy source 262, the intensity of energy emitted by the recoating assembly 200 can be distributed compared to a recoating assembly including a single energy source. This can reduce defects in the adhesive 50 and / or the build material 31. More specifically, the heat power density of a single energy source heating system can quickly reach its limit due to space and cost constraints. Excessive power output in a single energy source heating system is detrimental to the curing quality of the adhesive 50 in each layer of build material 31 because large temperature peaks can cause stress and cracking in relatively weak parts and can cause uncontrolled evaporation of the solvent within the adhesive 50. By including both a front energy source 260 and a rear energy source 262, the heat power intensity of the recoating assembly 200 can be distributed. In particular, as noted above, by including multiple energy sources (e.g., a front energy source 260 and a rear energy source 262), energy can be applied to the build material 31 over a relatively longer period of time compared to applying energy via a single energy source. Figure 1 A). In this way, over-curing of the building material 31 bonded by the cured adhesive 50 can be minimized.

[0162] Furthermore, since the recoating assembly 200 includes a front energy source 260 and a rear energy source 262, the operation of the recoating assembly 200 can be maintained even if either the front energy source 260 or the rear energy source 262 fails. In particular, by providing several energy sources (e.g., the front energy source 260 and the rear energy source 262 and / or other additional energy sources), if one energy source fails, another energy source can continue to be used, allowing the recoating assembly 200 to continue operating, thereby reducing the downtime of the recoating assembly 200.

[0163] In some embodiments, the first roller 204 rotates at a rotational speed sufficient to fluidize at least a portion of the building material 31. In some embodiments, the first roller 204 rotates at a rotational speed of at least 2.5 meters per second. In some embodiments, the first roller 204 rotates at a rotational speed of at least 2 meters per second. In some embodiments, the first roller 204 rotates at a rotational speed of at least 1 meter per second.

[0164] In some embodiments, the operation of the front energy source 260 and / or the rear energy source 262 can be controlled and modified. In an embodiment, the front energy source 260 and / or the rear energy source 262 can be communicatively connected to the electronic control unit 300 via one or more relays (such as solid-state relays), which facilitates the control of the front energy source 260 and / or the rear energy source 262.

[0165] In some embodiments, the additive manufacturing system 100 may include a temperature sensor 286 communicatively coupled to the electronic control unit 300. The temperature sensor 286 may include any contact or non-contact sensor suitable for detecting the temperature of the build material 31, such as, but not limited to, one or more infrared thermometers, thermocouples, thermopile, etc. Figure 6A As shown, one or more temperature sensors 286 may be positioned behind the first roller 202 and / or the second roller 204; however, it should be understood that one or more temperature sensors 286 may be coupled to the recoating assembly at any suitable location. In an embodiment, after irradiating the initial layer build material 31 and / or the second layer build material 31 with the front energy source 260, the method further includes detecting the temperature of the irradiated build material 31 using the temperature sensors 286. In some embodiments, the output of the front energy source 260 and / or the rear energy source 262 may be adjusted in response to the detected temperature of the build material 31 (e.g., feedback control). In some embodiments, the detected temperature may be stored so that the electronic control unit 300 can develop models for controlling the front energy source 260 and / or the rear energy source 262 (e.g., feedforward control). For example, in some embodiments, the method further includes changing at least one parameter of the front energy source 260 or the rear energy source 262, at least in part, based on the detected temperature. Furthermore, in some embodiments, irradiating at least one of the initial layer construction material 31 and the second layer construction material 31 with the front energy source 260 includes applying a predetermined power to the front energy source 260 or the rear energy source 262, the method further including changing the predetermined power at least in part based on the detected temperature.

[0166] In some embodiments, the recoating assembly 200 includes a distance sensor 288 communicatively coupled to the electronic control unit 300. The distance sensor 288 is generally configured to detect the thickness of a layer of build material 31 positioned beneath the recoating assembly 200. In an embodiment, the electronic control unit 300 can receive from the distance sensor 288 a signal instructing the layer of build material 31 to move to the build area 124. The electronic control unit 300 can change one or more parameters based on the detected thickness of the layer of build material 31, such that the recoating assembly 200 can move the build material 31 to the build area 124 as desired. In an embodiment, the distance sensor 288 may include any sensor suitable for detecting the thickness of the build material 31, such as, but not limited to, a laser sensor, an ultrasonic sensor, etc.

[0167] In some embodiments, the second roller 204 may be positioned above the first roller 202 in the vertical direction (i.e., in the depicted Z direction). In these embodiments, only the first roller 202 may contact the building material 31, and the second roller 204 may function as a backup roller that can be used in case the first roller 202 fails or malfunctions.

[0168] In some embodiments, the second roller 204 rotates in a rotation direction 62 opposite to the reverse rotation direction 60, and the second roller 204 contacts the build material 31 within the build region 124. The second roller 204 may rotate at a rotational rate corresponding to the linear rate of the recoating assembly 200. More specifically, by matching the rotational rate of the second roller 204 to match the linear rate of the recoating assembly 200, the second roller 204 can be used to substantially compact the build material 31 while causing minimal damage to the build material 31 as the recoating assembly 200 moves relative to the build region 124. In embodiments, the rotational rate of the first roller 202 is greater than the rotational rate of the second roller 204. In some embodiments, when the second roller 204 compacts the build material 31, the second roller 204 may be positioned lower than the first roller 202 in the vertical direction (i.e., in the depicted Z direction).

[0169] In some embodiments, once the second layer of build-up material 31 has been deposited, the first roller 202 moves upward in the vertical direction (e.g., in the depicted Z direction) such that the first roller 202 is spaced apart from the second layer of build-up material 31. Then, the recoating assembly 200 moves to the supply reservoir 134 in the direction opposite to the coating direction 31. Thus, the recoating assembly 200 can return to the original recoating position 148. Figure 2A In some embodiments, the recoating assembly 200 moves to the supply reservoir 134 at a return speed. In some embodiments, the return speed is greater than the application speed at which the recoating assembly 200 moves the fluidized build material 31 to the build area 124. In some embodiments, the application speed can be limited to avoid damaging the cured adhesive build material 31, thereby reducing the total cycle time required to deposit the build material 31 by increasing the return speed.

[0170] In some embodiments, the first roller 202 and / or the second roller 204 may compact the build material 31 in the build region 124 as the recoating assembly 200 moves back to its original position 148. For example, refer to Figure 29A and Figure 29B The recoating assembly 200 is depicted moving in the coating direction 40 and in a direction 42 opposite to the coating direction 40. In some embodiments, the method further includes rotating the first roller 202 and / or the second roller 204 in the reverse rotation direction 60. Rotating the first roller 202 and / or the second roller 204 in the reverse rotation direction 60 may include rotating the first roller 202 and / or the second roller 204 at a rotational rate corresponding to the linear rate at which the recoating assembly 200 moves toward the supply reservoir 134.

[0171] In some embodiments, before moving the recoating assembly 200 to the supply reservoir 134, the method further includes moving the first roller 202 and / or the second roller 204 upward in a vertical direction (i.e., in the depicted Z direction). In some embodiments, the first roller 202 and / or the second roller 204 are moved upward in the vertical direction between 8 micrometers and 12 micrometers, including the endpoints. In some embodiments, the first roller 202 and / or the second roller 204 are moved upward in the vertical direction about 10 micrometers. In some embodiments, before moving the recoating assembly 200 to the supply reservoir 134, the method further includes moving the first roller 202 and / or the second roller 204 upward in a vertical direction (i.e., in the depicted Z direction). In some embodiments, the first roller 202 and / or the second roller 204 are moved upward in the vertical direction between 5 micrometers and 20 micrometers, including the endpoints. By moving the first roller 202 and / or the second roller 204 upward in the vertical direction, the first roller 202 and / or the second roller 204 can be positioned to compact the build material 31 in the build region 124.

[0172] In some embodiments, as the first roller 202 and / or the second roller 204 contacts the build material 31 in the build area 124 and moves back toward the supply reservoir 134, the first roller 202 and / or the second roller 204 rotate at a rotational rate corresponding to the linear rate at which the recoating assembly 200 moves back toward the supply reservoir 134. As noted above, by relating the rotational rate of the first roller 202 and / or the second roller 204 to the linear rate of the recoating assembly 200, the first roller 202 and / or the second roller 204 can compact the build material 31, wherein the build material 31 is minimally damaged in the longitudinal direction (i.e., in the depicted X direction).

[0173] Although Figure 29A and Figure 29B This includes a supply reservoir 134; however, it should be understood that in some embodiments, a supply reservoir 134 is not provided, and instead, the building material 31 can be supplied via other means (such as a building material hopper 360). Figure 2B Place it on build area 124.

[0174] In some embodiments, as the recoating assembly 200 moves in the coating direction 40, the first roller 202 and the second roller 204 can rotate in the opposite rotation direction 60, such as... Figure 29C As shown in the diagram. In some embodiments, when the recoating assembly 200 moves in the coating direction 40, the first roller 202 is positioned above the second roller 204. When the recoating assembly 200 moves in the return direction 42, the first roller 202 and the second roller 204 can rotate in the rotation direction 62, as shown in the diagram. Figure 29DAs shown in the diagram. In some embodiments, when the recoating assembly 200 moves in the return direction 42, the first roller 202 is positioned below the second roller 204. Further, in some embodiments, when the recoating assembly 200 moves in the coating direction 40 ( Figure 29C And / or, when the recoating assembly 200 moves in the return direction 42, the front energy source 260 and / or the rear energy source 262 can irradiate the build material 31 in the build area 124.

[0175] refer to Figure 24 and Figure 30 The diagram schematically depicts an example method for extracting airborne build material 31 from a recoating assembly 200. In a first step 3002, the method includes moving the recoating assembly 200 over the build material 31 along a coating direction 40. In step 3004, the method further includes contacting the build material 31 with a powder spreading member, causing at least a portion of the build material 31 to become airborne. In step 3006, the method further includes extracting the airborne build material 31 from the recoating assembly 200 using a vacuum section 290 in fluid communication with the recoating assembly 200.

[0176] In an embodiment, each of steps 3002-3006 may be performed, for example, by an electronic control unit 300.

[0177] In embodiments, the vacuum unit 290 may extract the airborne build material 31 from the recoating assembly 200 once or multiple times during the build cycle. For example, in some embodiments, the step of extracting the airborne build material 31 from the recoating assembly 200 occurs after or during the step of moving the build material 31. Alternatively, the vacuum unit 290 may extract the build material 31 from the recoating assembly 200 at the end of the build cycle. In some embodiments, the step of extracting the airborne build material 31 from the recoating assembly 200 may be performed simultaneously with the step of moving the build material 31. Alternatively, the airborne build material 31 may be extracted from the recoating assembly 200 in a continuous or semi-continuous manner during the build cycle.

[0178] In some embodiments, the vacuum unit 290 may apply positive pressure to the recoating assembly 200 to remove build-up material 31 accumulated within the recoating assembly 200. For example, in some embodiments, after the build-up material 31 is moved, the vacuum unit 290 directs a process gas (such as air) to the recoating assembly 200. In some embodiments, the vacuum unit 290 may apply positive pressure while the recoating assembly 200 is positioned over an outlet where negative pressure is applied to collect the build-up material 31. In an embodiment, the outlet may be positioned in the build region 134 ( Figure 2A )nearby.

[0179] Based on the foregoing, it should be understood that the embodiments described herein are for recoating assemblies used in additive manufacturing systems. In the embodiments described herein, the recoating assembly includes one or more sensors that detect forces acting on the recoating assembly. By detecting the forces acting on the recoating assembly, defects can be identified, and one or more parameters related to the operation of the recoating assembly can be adjusted to optimize its performance. In some embodiments, the recoating assembly described herein may include multiple redundant components, such as rollers and power sources, so that the recoating assembly can continue to operate in the event of a failure of one or more components. In some embodiments, the recoating assembly described herein is fluidly connected to a vacuum unit, which collects and contains build-up material from the air.

[0180] Further aspects of the invention are provided by way of the subject matter of the following provisions:

[0181] 1. A method for forming an object, the method comprising: moving a recoating assembly on a build material in a coating direction, wherein the recoating assembly includes a first roller and a second roller, the second roller being spaced apart from the first roller; rotating the first roller of the recoating assembly in a counter-rotational direction such that the bottom of the first roller moves in the coating direction; contacting the build material with the first roller of the recoating assembly, thereby fluidizing at least a portion of the build material; irradiating an initial layer of build material positioned in a build region using a front energy source coupled to a front end of the recoating assembly; after irradiating the initial layer of build material, spreading the build material onto the build region using the first roller, thereby depositing a second layer of build material onto the initial layer of build material; and after spreading the second layer of build material, irradiating the second layer of build material within the build region using a rear energy source positioned behind the front energy source.

[0182] 2. As described in any of the preceding clauses, wherein the second roller is positioned vertically above the first roller such that the second roller does not contact the building material.

[0183] 3. As described in any of the preceding clauses, wherein the first roller is a front roller and the second roller is a rear roller positioned behind the first roller.

[0184] 4. The method described in any of the preceding clauses further comprises: rotating the rear roller in a rotational direction opposite to the reverse rotation direction; and bringing the second layer of build material within the build area into contact with the rear roller.

[0185] 5. The method as described in any of the preceding clauses, wherein rotating the rear roller in the rotational direction comprises rotating the rear roller at a rotational speed corresponding to the linear speed of the recoating assembly.

[0186] 6. The method described in any of the preceding clauses further comprises, after irradiating at least one of the initial layer of the building material with a front energy source and the second layer of the building material with a rear energy source, detecting the temperature of the irradiated building material using a temperature sensor.

[0187] 7. As described in any of the preceding clauses, the method further comprises, at least in part, altering at least one parameter of the preceding or following energy source based on the detected temperature.

[0188] 8. The method as described in any of the preceding clauses, wherein at least one of irradiating the initial layer construction material with a front energy source and irradiating the second layer construction material with a rear energy source comprises applying a predetermined power to the front energy source or the rear energy source, the method further comprising changing the predetermined power at least in part based on a detected temperature.

[0189] 9. A method for forming an object, the method comprising: moving a recoating assembly over a build material, wherein the recoating assembly includes a first roller and a second roller, the second roller being spaced apart from the first roller; moving the second roller above the first roller in a vertical direction; rotating the first roller of the recoating assembly in an anti-rotational direction such that the bottom of the first roller moves in a coating direction; contacting the build material with the first roller of the recoating assembly while the second roller is spaced apart from the build material in a vertical direction, thereby fluidizing at least a portion of the build material; and moving the fluidized build material using the first roller, thereby depositing a second layer of build material on an initial layer of build material positioned in a build region.

[0190] 10. The method described in any of the preceding clauses further comprises, after depositing the second layer of build material, moving the first roller upward in a vertical direction such that the first roller is spaced apart from the second layer of build material, and moving the recoating assembly to its original position in a direction opposite to the coating direction.

[0191] 11. The method as described in any of the preceding clauses, wherein moving the recoating component to its original position comprises moving the recoating component at a return velocity, and wherein moving the fluidized build material comprises moving the recoating component in the coating direction at a coating velocity, wherein the return velocity is greater than the coating velocity.

[0192] 12. The method described in any of the preceding clauses further comprises, before moving the recoating component to its original position, lowering the second roller such that the second roller contacts the second layer of building material.

[0193] 13. As described in any of the preceding clauses, the method further comprises rotating the second roller in the reverse rotation direction.

[0194] 14. The method as described in any of the preceding clauses, wherein rotating the second roller in the reverse rotation direction comprises rotating the second roller at a rotational speed corresponding to the linear velocity at which the recoating assembly moves to its original position.

[0195] 15. The method as described in any of the preceding clauses, wherein the second roller comprises a second roller diameter and the first roller comprises a first roller diameter, wherein the second roller diameter is greater than the first roller diameter.

[0196] 16. The method described in any of the preceding clauses further comprises irradiating the initial layer build material located in the build area with a front energy source coupled to the front end of the recoating component.

[0197] 17. The method described in any of the preceding clauses further comprises, after moving the second layer of build material, irradiating the second layer of build material within the build area using a post-energy source coupled to the recoating assembly.

[0198] 18. A method for forming an object, the method comprising: moving a recoating assembly over a build material, wherein the recoating assembly includes a front roller and a rear roller spaced apart from the front roller; rotating the front roller of the recoating assembly in a counter-rotation direction such that the bottom of the front roller moves in a coating direction; contacting the build material with the front roller of the recoating assembly, thereby fluidizing at least a portion of the build material; moving the fluidized build material to deposit a second layer of build material onto an initial layer of build material positioned in a build region; rotating the rear roller of the recoating assembly in a rotation direction opposite to the counter-rotation direction; and contacting the build material with the rear roller after the build material has contacted the front roller.

[0199] 19. As described in any of the preceding clauses, wherein at least a portion of the rear roller is positioned vertically below the front roller.

[0200] 20. The method described in any of the preceding clauses, wherein rotating the rear roller in the rotational direction comprises rotating the rear roller at a rotational speed corresponding to the linear velocity of the recoating assembly.

[0201] 21. The method as described in any of the preceding clauses, wherein rotating the front roller comprises rotating the front roller at a front roller rotation speed, and rotating the rear roller comprises rotating the rear roller at a rear rotation speed, wherein the front roller rotation speed is greater than the rear rotation speed.

[0202] 22. The method as described in any of the preceding clauses further includes, after depositing the second layer of build material in the supply reservoir, moving the front roller and the rear roller vertically upward such that the front roller and the rear roller are spaced apart from the second layer of build material, and moving the recoating assembly to its original position in a direction opposite to the coating direction.

[0203] 23. The method as described in any of the preceding clauses, wherein moving the recoating component to the original position comprises moving the recoating component at a return velocity, and wherein moving the fluidized build material comprises moving the recoating component at a coating velocity in the coating direction, wherein the return velocity is greater than the coating velocity.

[0204] 24. The method described in any of the preceding clauses further comprises irradiating the initial layer building material with a front energy source coupled to the front end of the coating assembly.

[0205] 25. The method described in any of the preceding clauses further includes irradiating the second layer of the building material with a post-energy source coupled to the rear end of the coating assembly after the second layer of building material has been moved.

[0206] 26. A method for forming an object, the method comprising: moving a recoating assembly over a build material, wherein the recoating assembly includes a roller rotatably coupled to a substrate member; rotating the roller of the recoating assembly in a counter-rotation direction such that the bottom of the roller moves in a coating direction; contacting the build material with the roller of the recoating assembly to fluidize at least a portion of the build material; moving the fluidized build material with the roller to deposit a second layer of build material on an initial layer of build material located in a build region; after depositing the second layer of build material, rotating the roller of the recoating assembly in the counter-rotation direction; moving the recoating assembly in a direction opposite to the coating direction; and contacting the second layer of build material with the roller while moving in the direction opposite to the coating direction.

[0207] 27. The method described in any of the preceding clauses further includes moving the roller upward in a vertical direction before moving the coating assembly in a direction opposite to the coating direction.

[0208] 28. The method as described in any of the preceding clauses, wherein moving the roller upward in the vertical direction comprises moving the roller between 5 micrometers and 20 micrometers in the vertical direction.

[0209] 29. The method described in any of the preceding clauses, wherein contacting the second layer of building material comprises rotating the roller at a rotational speed corresponding to the linear speed at which the recoating assembly is moved to the supply reservoir.

[0210] 30. A recoating assembly for an additive manufacturing system, the recoating assembly comprising a substrate member, a front roller rotatably coupled to the substrate member, a rear roller rotatably coupled to the substrate member, a front energy source coupled to the substrate member and located in front of the front roller, and a rear energy source, the rear energy source being coupled to the substrate member and positioned behind the front energy source, wherein the front roller and the rear roller are spaced apart, wherein the front energy source emits energy in front of the front roller, and wherein the rear energy source emits energy behind the front energy source.

[0211] 31. The recoating assembly as described in any of the preceding clauses further includes a vertical actuator and a base member coupled to at least one of the front and rear rollers, wherein the vertical actuator moves at least one of the front and rear rollers in a vertical direction relative to the base member.

[0212] 32. Any recoating assembly as described in the preceding clause further includes a hard stop that restricts the vertical movement of at least one of the front and rear rollers.

[0213] 33. Any repainting component as described in the preceding clause further includes a dust cover that at least partially seals off the hard stop.

[0214] 34. The recoating assembly as described in any of the preceding clauses, wherein the vertical actuator is coupled to the front roller and the rear roller such that the front roller and the rear roller can move independently of each other relative to the base member.

[0215] 35. The recoating assembly as described in any of the preceding clauses, wherein the vertical actuator is a first vertical actuator coupled to the front roller, and the recoating assembly further includes a second vertical actuator coupled to the rear roller, wherein the second vertical actuator moves the rear roller in a vertical direction relative to the substrate member.

[0216] 36. Any recoating assembly as described in the preceding clause, wherein the front roller has a front roller diameter and the rear roller has a rear roller diameter, wherein the front roller diameter and the rear roller diameter are different.

[0217] 37. Any recoating assembly as described in the preceding clause, wherein the diameter of the front roller is smaller than the diameter of the rear roller.

[0218] 38. The recoating assembly as described in any of the preceding clauses further includes a powder bonding member coupled to the base member and positioned at a height in front of the front roller within the roller window defined by the front roller.

[0219] 39. Any recoating assembly as described in the preceding clause further includes a housing engagement member positioned at an outer end of the recoating assembly and engaging with a housing therein.

[0220] 40. Any recoating assembly as described in the preceding clause further includes a third roller rotatably coupled to the base member, wherein the third roller is aligned in a lateral direction with one of the front roller or the rear roller.

[0221] 41. The recoating assembly as described in any of the preceding clauses further includes a third roller rotatably coupled to the base member, wherein the third roller overlaps with at least one of the front roller and the rear roller in the lateral direction.

[0222] 42. A recoating assembly for an additive manufacturing system, the recoating assembly comprising a substrate member, a first roller rotatably coupled to the substrate member, and a second roller rotatably coupled to the substrate member, the first roller having a first roller diameter, wherein the second roller is spaced apart from the first roller and has a second roller diameter, wherein the second roller diameter is larger than the first roller diameter.

[0223] 43. The recoating assembly as described in any of the preceding clauses, wherein the first roller is a front roller and the second roller is a rear roller, wherein the front roller is positioned in front of the rear roller.

[0224] 44. Any recoating assembly as described in the preceding clause further includes a front energy source coupled to the base member and positioned in front of the front roller, and a rear energy source coupled to the base member and positioned behind the front energy source, wherein the front energy source emits energy in front of the front roller.

[0225] 45. The recoating assembly as described in any of the preceding clauses further includes a powder bonding member coupled to the base member and positioned in front of the front roller at a height within the roller window defined by the front roller.

[0226] 46. ​​Any recoating assembly as described in the preceding clause further includes a housing engagement member positioned at an outer end of the recoating assembly and engaging with a housing therein.

[0227] 47. Any recoating component as described in the preceding clause further includes a cleaning component engaged with at least one of the first roller and the second roller.

[0228] 48. Any recoating assembly as described in the preceding clause further includes a cleaning position adjustment assembly, said cleaning position adjustment assembly being structurally configured to move the position of the cleaning member relative to the first roller and the second roller.

[0229] 49. Any recoating component as described in the preceding clause further includes a pivot guide pivotally coupled to the base member.

[0230] 50. Any recoating assembly as described in the preceding clause, wherein the first roller is a rear roller and the second roller is a front roller located in front of the rear roller.

[0231] 51. Any recoating assembly as described in the preceding clause further includes a third roller aligned in the lateral direction with the front roller, wherein the rear roller extends in the lateral direction between the third roller and the front roller.

[0232] 52. Any recoating assembly as described in the preceding clause, wherein the rear roller extends through the gap defined by the front roller and the third roller.

[0233] 53. An additive manufacturing system comprising a substrate member, a recoating assembly lateral actuator coupled to the substrate member, a front roller rotatably coupled to the substrate member, a rear roller rotatably coupled to the substrate member, a vertical actuator coupled to at least one of the front roller and the rear roller and the substrate member, and an electronic control unit communicatively coupled to the vertical actuator, wherein the recoating assembly lateral actuator moves the substrate member in a lateral direction, wherein the front roller is spaced apart from the substrate member, and wherein the vertical actuator moves at least one of the front roller and the rear roller in a vertical direction relative to the substrate member.

[0234] 54. The system as described in any of the preceding clauses further includes a front energy source coupled to the base member and located in front of the front roller, and a rear energy source coupled to the base member and located behind the rear roller, wherein the front energy source emits energy in front of the front roller, and the rear energy source emits energy behind the rear roller.

[0235] 55. The system as described in any of the preceding clauses further includes a rotary actuator coupled to the front roller and communicatively coupled to an electronic control unit, wherein the electronic control unit directs the recoating assembly lateral actuator to move the substrate member in a coating direction extending in the lateral direction, and directs the rotary actuator to rotate the front roller in a direction that causes the bottom of the front roller to move in the coating direction.

[0236] 56. The system described in any of the preceding clauses, wherein the electronic control unit directs the rotary actuator to rotate the front roller at a rotational speed of at least 1 meter per second.

[0237] 57. The system as described in any of the preceding clauses, wherein the rotary actuator is a front rotary actuator, and the system further includes a rear rotary actuator coupled to the rear roller and communicatively coupled to the electronic control unit, wherein the electronic control unit further directs the rear rotary actuator to rotate the rear roller in a direction opposite to that of the front roller.

[0238] 58. The system as described in any of the preceding clauses, wherein the electronic control unit directs the rear rotary actuator to rotate the rear roller at a rotational speed corresponding to the speed at which the substrate member moves in the coating direction.

[0239] 59. The system as described in any of the preceding clauses, wherein the electronic control unit guides the vertical actuator to position the front and rear rollers at different heights assessed along the vertical direction.

[0240] 60. Any system described in the preceding clause also includes a tilt actuator that positions the front and rear rollers at different heights by tilting the base member.

[0241] 61. The system as described in any of the preceding clauses further includes a base member rotary actuator coupled to the base member and communicatively coupled to the electronic control unit, wherein the electronic control unit guides the base member rotary actuator about a vertical direction, the vertical direction being transverse to the lateral direction.

[0242] 62. The system as described in any of the preceding clauses, wherein the front roller has a front roller diameter and the rear roller has a rear roller diameter, wherein the front roller diameter and the rear roller diameter are different.

[0243] 63. The system described in any of the preceding clauses, wherein the diameter of the front roller is smaller than the diameter of the rear roller.

[0244] 64. Any system described in the preceding clause also includes a distance sensor communicatively coupled to the electronic control unit.

[0245] 65. The system as described in any of the preceding clauses, wherein the electronic control unit receives from a distance sensor a signal indicating the thickness of a building material layer located beneath the system.

[0246] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Therefore, this specification is intended to cover modifications and variations of the various embodiments described herein, if such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. A method for forming an object, characterized in that, The method includes: A recoating assembly is moved in a coating direction on a building material, wherein the recoating assembly includes a first roller and a second roller, the second roller being spaced apart from the first roller; The first roller of the recoating assembly is rotated in the opposite rotation direction, such that the bottom of the first roller moves in the coating direction; The build-up material is brought into contact with the first roller of the recoating assembly, thereby fluidizing at least a portion of the build-up material; Using a front energy source connected to the front end of the recoating assembly, the initial layer build material positioned in the build area is irradiated; After irradiating the initial layer construction material, the construction material is spread onto the construction area using the first roller, thereby depositing a second layer construction material on the initial layer construction material; and After the second layer of building material is spread out, the second layer of building material in the building area is irradiated by a rear energy source positioned behind the front energy source. The recoating component further includes: Base components; A vertical actuator, the vertical actuator being coupled to at least one of the first roller and the second roller and coupled to a pivoting portion of the base member, the pivoting portion being movable relative to a stationary portion of the base member, wherein the first roller and the second roller are coupled to the pivoting portion, and wherein the vertical actuator moves at least one of the first roller and the second roller in a vertical direction relative to the base member; and A rigid stop having a connecting portion and a column portion, the connecting portion being connected to the pivot portion and the column portion being movably engaged with the stationary portion; The coating direction is in the X-axis direction and the vertical direction is in the Z-axis direction, and the rigid stop restricts the movement of at least one of the first roller and the second roller about a Y-axis perpendicular to the X-axis and the Z-axis.

2. The method according to claim 1, characterized in that, in, The second roller is positioned vertically above the first roller so that the second roller does not contact the building material.

3. The method according to claim 1, characterized in that, in, The first roller is a front roller, and the second roller is a rear roller located behind the first roller.

4. The method according to claim 3, characterized in that, Further includes: The rear roller is rotated in a direction opposite to the reverse rotation direction; and The second layer of building material within the building area is brought into contact with the rear roller.

5. The method according to claim 4, characterized in that, in, Rotating the rear roller in the rotational direction includes rotating the rear roller at a rotational speed corresponding to the linear speed of the recoating assembly.

6. The method according to claim 1, characterized in that, It further includes detecting the temperature of the irradiated building material using a temperature sensor after irradiating at least one of the initial layer building material with the front energy source and the second layer building material with the rear energy source.

7. The method according to claim 6, characterized in that, It further includes, at least in part, altering at least one parameter of the front energy source or the rear energy source based on the detected temperature.

8. The method according to claim 6, characterized in that, in, The method comprises irradiating the initial layer construction material with the front energy source and irradiating the second layer construction material with the rear energy source by at least one of applying a predetermined power to the front energy source or the rear energy source; the method further comprises changing the predetermined power at least in part based on a detected temperature.

9. A method for forming an object, characterized in that, The method includes: A recoating assembly is moved on a building material, wherein the recoating assembly includes a first roller and a second roller, the second roller being spaced apart from the first roller; The second roller, positioned above the first roller, is moved vertically. The first roller of the recoating assembly is rotated in the opposite rotation direction, such that the bottom of the first roller moves in the coating direction; While the second roller is spaced apart from the build material in the vertical direction, the build material is brought into contact with the first roller of the recoating assembly, thereby fluidizing at least a portion of the build material; and The first roller moves the fluidized build material, thereby depositing a second layer of build material on the initial layer of build material located in the build region; The recoating component further includes: Base components; A vertical actuator, the vertical actuator being coupled to at least one of the first roller and the second roller and coupled to a pivoting portion of the base member, the pivoting portion being movable relative to a stationary portion of the base member, wherein the first roller and the second roller are coupled to the pivoting portion, and wherein the vertical actuator moves at least one of the first roller and the second roller in a vertical direction relative to the base member; and A rigid stop having a connecting portion and a column portion, the connecting portion being connected to the pivot portion and the column portion being movably engaged with the stationary portion; The coating direction is in the X-axis direction and the vertical direction is in the Z-axis direction, and the rigid stop restricts the movement of at least one of the first roller and the second roller about a Y-axis perpendicular to the X-axis and the Z-axis.

10. The method according to claim 9, characterized in that, The method further includes, after depositing the second layer of building material, moving the first roller upward in the vertical direction such that the first roller is spaced apart from the second layer of building material, and moving the recoating assembly to its original position in a direction opposite to the coating direction.

11. The method according to claim 10, characterized in that, in, Moving the recoating component to the original position includes moving the recoating component at a return velocity, and wherein moving the fluidized build material includes moving the recoating component in the coating direction at a coating velocity, wherein the return velocity is greater than the coating velocity.

12. The method according to claim 10, characterized in that, It further includes lowering the second roller so that it contacts the second layer of building material before moving the recoating assembly to the original position.

13. The method according to claim 12, characterized in that, It further includes rotating the second roller in the reverse rotation direction.

14. The method according to claim 13, characterized in that, in, Rotating the second roller in the reverse rotation direction includes rotating the second roller at a rotational speed corresponding to the linear velocity at which the recoating assembly moves to the original position.

15. The method according to claim 12, characterized in that, in, The second roller includes a second roller diameter, and the first roller includes a first roller diameter, wherein the second roller diameter is larger than the first roller diameter.

16. The method according to claim 9, characterized in that, It further includes irradiating the initial layer building material positioned in the building region with a front energy source connected to the front end of the recoating assembly.

17. The method according to claim 9, characterized in that, It further includes irradiating the second layer of the building material within the building area using a post-energy source connected to the recoating assembly after the second layer of building material has been moved.

18. A recoating component for an additive manufacturing system, characterized in that, The recoating component includes: Base components; A front roller, which is rotatably coupled to the base member; A rear roller, rotatably coupled to the base member, wherein the front roller is spaced apart from the rear roller; A front energy source is connected to the base member and positioned in front of the front roller, wherein the front energy source emits energy in front of the front roller; A rear energy source, which is connected to the base member and positioned behind the front energy source, wherein the rear energy source emits energy behind the front energy source; A vertical actuator is coupled to at least one of the front roller and the rear roller and to a pivot portion of the base member, the pivot portion being movable relative to a stationary portion of the base member, wherein the front roller and the rear roller are coupled to the pivot portion, and wherein the vertical actuator moves at least one of the front roller and the rear roller in a vertical direction relative to the base member. as well as A rigid stop having a connecting portion and a column portion, the connecting portion being connected to the pivot portion and the column portion being movably engaged with the stationary portion; The bottom of the front roller or the rear roller moves in the X-axis direction and the vertical direction is in the Z-axis direction, and the hard stop restricts the movement of at least one of the front roller and the rear roller about a Y-axis perpendicular to the X-axis and the Z-axis.

19. The recoating assembly according to claim 18, characterized in that, It further includes a dust cover that at least partially seals the rigid stop.

20. The recoating assembly according to claim 18, characterized in that, The vertical actuator is coupled to the front roller and the rear roller, such that the front roller and the rear roller can move independently of each other relative to the base member.

21. The recoating component according to claim 20, characterized in that, in, The vertical actuator is a first vertical actuator coupled to the front roller, and the recoating assembly further includes a second vertical actuator coupled to the rear roller, wherein the second vertical actuator moves the rear roller in a vertical direction relative to the base member.

22. The recoating assembly according to claim 18, characterized in that, in, The front roller has a front roller diameter, and the rear roller has a rear roller diameter, wherein the front roller diameter and the rear roller diameter are different.

23. The recoating assembly according to claim 18, characterized in that, It further includes a powder bonding member, which is coupled to the base member and positioned in front of the front roller at a height within the roller window defined by the front roller.

24. A recoating component for an additive manufacturing system, characterized in that, The recoating component includes: Base components; A first roller, rotatably coupled to the base member, having a first roller diameter; A second roller, rotatably coupled to the base member, wherein the second roller is spaced apart from the first roller and has a second roller diameter, wherein the second roller diameter is larger than the first roller diameter; A vertical actuator is coupled to at least one of the first roller and the second roller and to a pivot portion of the base member, the pivot portion being movable relative to a stationary portion of the base member, wherein the first roller and the second roller are coupled to the pivot portion, and wherein the vertical actuator moves at least one of the first roller and the second roller in a vertical direction relative to the base member; as well as A rigid stop having a connecting portion and a column portion, the connecting portion being connected to the pivot portion and the column portion being movably engaged with the stationary portion; The bottom of the first roller or the second roller moves in the X-axis direction and the vertical direction is in the Z-axis direction, and the hard stop restricts the movement of at least one of the first roller and the second roller about a Y-axis that is perpendicular to the X-axis and the Z-axis.

25. The recoating component according to claim 24, characterized in that, The first roller is a front roller, and the second roller is a rear roller, wherein the front roller is positioned in front of the rear roller.

26. The recoating component according to claim 25, characterized in that, It further includes a front energy source coupled to the base member and positioned in front of the front roller, wherein the front energy source emits energy in front of the front roller; as well as A rear energy source that is connected to the base component and positioned behind the front energy source.

27. The recoating component according to claim 26, characterized in that, It further includes a powder bonding member coupled to the base member and positioned in front of the front roller at a height within the roller window defined by the front roller.

28. The recoating component according to claim 24, characterized in that, It further includes a cleaning member that engages with at least one of the first roller and the second roller.

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