# US 12,759,229 B2 · Devices and methods for three-dimensional printing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,229 B2 - Document ID: US12759229B2 - Status: Granted - Kind: B2 - Application number: 18/905,114 - Filed: 2024-10-02 - Published: 2025-01-23 - Granted: 2026-10-13 - Earliest claimed: 2016-08-03 - Assignees: 3DEO, Inc. - Applicants: 3DEO, Inc. - Inventors: Payman Torabi; Matthew Petros - Web page: https://patentgrep.com/patent/US12759229B2 ## CPC - B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber - B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} - B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) - B22F 10/14: by jetting of binder onto a bed of metal powder - B22F 10/66: by mechanical means - B33Y 10/00: Processes of additive manufacturing - B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - B22F 2003/247: {Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface} - B22F 10/32: of the atmosphere, e.g. composition or pressure in a building chamber - B22F 10/50: Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up - B22F 10/80: Data acquisition or data processing - B22F 12/10: Auxiliary heating means - B22F 12/41: characterised by the type, e.g. laser or electron beam - B22F 12/45: Two or more - B22F 12/53: Nozzles - B22F 2998/10: Processes characterised by the sequence of their steps - B22F 3/1021: {Removal of binder or filler (removal of binder from ceramics C04B35/638)} - B22F 3/26: Impregnating {(making ferrous alloys by impregnation C22C33/0242)} - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B22F 3/003: {Apparatus, e.g. furnaces (in general F27B)} - B22F 2202/01: Use of vibrations - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING ## Abstract The present disclosure provides systems and methods for the formation of three-dimensional objects. A method for forming a three-dimensional object may comprise alternately and sequentially applying a stream comprising a binding substance to an area of a layer of powder material in a powder bed, and generating at least one perimeter of the three-dimensional object in the area. The stream may be applied in accordance with a model design of the three-dimensional object. The at least one perimeter may generated in accordance with the model design. ## Claims ### Claim 1 A system for forming a three-dimensional object, comprising: a powder dispenser configured to deposit a powder material; a binding substance applicator configured to apply a binding substance to bind the deposited powder material, wherein the binding substance applicator comprises a binder tank that holds the binding substance and an ultrasonic mist generator system fluidically coupled to the binder tank to deliver the binding substance onto the deposited powder material when the binder tank is filled with the binding substance, a honeycomb structure path through which the binding substance flows, the binder tank comprising a float valve configured to control a level of the binding substance; and a perimeter generator configured to generate a perimeter by removing a portion of the powder material bound by the binding substance delivered by the ultrasonic mist generator system based on a model design of the three-dimensional object, thereby generating the three-dimensional object. ### Claim 2 (depends on 1) The system of claim 1, wherein the ultrasonic mist generator system comprises at least one ultrasonic transducer submerged by a specific distance under a surface of the binding substance contained in the binder tank. ### Claim 3 (depends on 1) The system of claim 1, wherein the binding substance applicator comprises a honeycomb structure path through which the binding substance flows. ### Claim 4 (depends on 1) The system of claim 1, wherein the powder material comprises at least one of a metal, a polymer, a metal alloy, a ceramic, or a cermet. ### Claim 5 (depends on 1) The system of claim 1, wherein the binding substance comprises a solvent, a liquid, a gel, a viscous solution, a sugar, a glue, a polymer, or a resin. ### Claim 6 (depends on 1) The system of claim 1, wherein the perimeter generator comprises a contact cutter. ### Claim 7 (depends on 6) The system of claim 6, wherein the contact cutter is a multi-axis machine tool or a computer numeric control (CNC) unit. ### Claim 8 (depends on 1) The system of claim 1, wherein the perimeter generator comprises a non-contact cutter or an air knife. ### Claim 9 (depends on 8) The system of claim 8, wherein the non-contact cutter is a laser. ### Claim 10 (depends on 1) The system of claim 1, further comprising an energy source that is configured to direct an energy beam to a portion of the powder material. ### Claim 11 (depends on 1) The system of claim 1, further comprising a smoother configured to smooth a top surface of the powder material. ### Claim 12 (depends on 1) The system of claim 1, wherein: the powder material is a first powder material, the powder dispenser is a first powder dispenser, and the system further comprises a second powder dispenser configured to deposit a second powder material to form part of the three-dimensional object, the second powder material being different from the first powder material. ### Claim 13 (depends on 1) The system of claim 1, further comprising one or more computer processors individually or collectively programmed to perform operations including: causing the powder dispenser to deposit a layer of the powder material; causing the binding substance applicator to apply the binding substance to the layer of the powder material; and causing the perimeter generator to generate, based on the model design of the three-dimensional object, a perimeter corresponding to the three-dimensional object by removing a portion of the layer including the powder material bound by the binding substance. ### Claim 14 (depends on 13) The system of claim 13, wherein the operations further comprise, subsequent to generating the perimeter, causing the powder dispenser to deposit an additional layer of the powder material on the layer; causing the binding substance applicator to apply the binding substance to the additional layer of the powder material; and causing the perimeter generator to generate an additional perimeter corresponding to the three-dimensional object in the additional layer by removing a portion of the powder material bound by the binding substance, wherein the additional perimeter is based on the model design of the three-dimensional object. ### Claim 15 (depends on 1) The system of claim 1, further comprising a furnace configured to heat the three-dimensional object. ### Claim 16 A method for generating a three-dimensional object, comprising depositing, by a powder dispenser, a layer of a powder material; applying, by a binding substance applicator, a binding substance to the layer of the powder material, wherein the binding substance applicator comprises a binder tank that holds the binding substance and an ultrasonic mist generator system fluidically coupled to the binder tank to deliver the binding substance onto the deposited powder material when the binder tank is filled with the binding substance, the binder tank comprising a float valve configured to control a level of the binding substance; and generating, by a perimeter generator, a perimeter corresponding to the three-dimensional object by removing, based on a model design of the three-dimensional object, a portion of the layer including the powder material bound by the binding substance. ### Claim 17 (depends on 16) The method of claim 16, further comprising: removing unbound powder material from the bound powder material. ### Claim 18 (depends on 17) The method of claim 17, wherein the unbound powder material is removed by a vacuum, suction, or dusting. ### Claim 19 (depends on 16) The method of claim 16, wherein: the powder material is a first powder material, the binding substance applicator is a first binding substance applicator, and the method further comprises depositing, by a second powder dispenser, a second powder material in the layer, the second powder material being different from the first powder material. ### Claim 20 (depends on 1) The system of claim 1, wherein the ultrasonic mist generator system comprises a fan configured to direct a mist of the binding substance through a spray outlet and toward the deposited powder material.