Method of, and apparatus for, applying flowable material across a surface

A method of applying flowable particulate material across a surface of a substrate in individual superimposed layers to produce a three-dimensional object by selective solidification of the successive layers, said method comprising:

• uniformly distributing flowable particulate material within a charging container,
• transferring flowable particulate material from the charging container to a metering shaft,
• discharging flowable particulate material downward in a continuous layer onto a surface of a substrate forming a uniform surface by moving the metering shaft and the charging container back and forth together over the surface of the substrate;
• while the metering shaft is depositing flowable particulate material, refilling the metering shaft to maintain a constant filling height of flowable particulate material in the metering shaft by transferring flowable particulate material from the charging container to the metering shaft.

An application apparatus for applying flowable particulate material across a surface of a substrate in individual superimposed layers, said apparatus comprising:

• an elongated metering shaft having
• a pair of opposing walls angled relative to each other,
• an open top formed between said pair of opposing walls, and
• a slot along a bottom of said measuring shaft between said pair of opposing walls, the slot is narrower between said opposing walls than the opening;
• a charging container which is open in an upward direction away from said metering shaft and located above said metering shaft, said charging container having a slot in a side wall proximate to a bottom of said charging container with a cavity from the slot to a top of said charging container, the slot is in communication with the open top of said metering shaft;
• said charging container includes a distribution device in the cavity spaced from the slot of said charging container;
• said metering shaft and said charging container move together across a substrate and form a pathway for flowable particulate material to travel and be deposited on the substrate from said metering shaft while maintaining a substantially constant filing height of flowable particulate material in said metering shaft.

An application apparatus for applying flowable particulate material across a surface of a substrate in individual superimposed layers, said apparatus comprising:

• an elongated metering shaft having
• a pair of opposing walls angled relative to each other,
• an open top formed between said pair of opposing walls, and
• a slot along a bottom of said measuring shaft between said pair of opposing walls, the slot is narrower between said opposing walls than the opening;
• a charging container which is open in an upward direction away from said metering shaft and located above said metering shaft, said charging container having a slot in a side wall proximate to a bottom of said charging container with a cavity from the slot to a top of said charging container, the slot is in communication with the open top of said metering shaft;
• said metering shaft and said charging container move together across a substrate and form a pathway for flowable particulate material to travel and be deposited on the substrate from said metering shaft while maintaining a substantially constant filing height of flowable particulate material in said metering shaft.