Three-dimensional printing system with self-maintaining powder distribution subsystem

A method of manufacturing a three-dimensional article comprising:

• accreting a layer of selectively fused powder onto an upper surface, the upper surface is one of an upper surface of a build plate and an upper surface of a powder layer, according to the steps of:
• positioning the upper surface proximate to a build plane;
• scanning a powder coater over the upper surface along a scan axis;
• concurrent with scanning, metering a layer of unfused powder onto the upper surface;
• and
• operating a beam system to selectively fuse the metered layer of powder;
• repeat accreting layers of powder above the build plate;
• and
• after accreting N layers, in which N is at least one, remove accumulated powder residue from surfaces of the powder coater according to the steps of:
• positioning the powder coater over a location that is laterally outside of the build plane;
• and
• operating a vibration generator to shake the accumulated powder from an upper outside surface of the powder coater onto the location outside of the build plane.

A three-dimensional printing system for manufacturing a three-dimensional article comprising:

• a build chamber;
• an overflow chamber adjacent to the build chamber;
• a motorized build plate;
• a powder coater including a vibration generator;
• a powder hopper;
• a lateral movement mechanism;
• a beam system;
• and
• a controller configured to:
• (1) position an upper surface proximate to a build plane, the upper surface is one of an upper surface of a build plate and an upper surface of a previously deposited powder layer;
• (2) operate the lateral movement mechanism to scan the powder coater over the build plane;
• (3) concurrent with scanning, operate the powder coater to meter a layer of unfused powder onto the upper surface;
• (4) operate the beam system to selectively fuse the metered layer of powder;
• (5) repeat (1)-(4) until the three-dimensional article is fabricated;
• (6) replenish the powder coater with powder using the powder hopper after selectively fusing M layers, M is at least one;
• and
• (7) move the powder coater to the overflow chamber and operate the vibration generator after selectively fusing N layers, N is at least two, operating the vibration generator shakes powder from an upper outside surface of the powder coater and into the overflow chamber.