Patent ID: 9586290
Date: 2017-03-07
CPC Classifications: B22F,B23K,B28B,B29C,B29K,B33Y,C04B,C22C,H05B,Y02P

Claim:
1. A system for forming a three-dimensional object, comprising: a powder dispenser that dispenses a powder material to form at least a portion of a powder bed comprising a first exposed surface, which powder bed is adjacent to the powder dispenser that is laterally translatable with respect to the powder bed; a powder removal member that is disposed above the powder bed and is laterally translatable with respect to the powder bed, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, wherein the powder removal member comprises an opening for removing powder material from the powder bed; an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object; a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface.