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© Marzky Ragsac Jr./Fotolia In most processes the starting material is a fine plastic or metal powder. Typically, the powder is stored in cartridges or beds from which it is dispensed in small amounts and spread by a roller or blade in an extremely thin layer (commonly only the thickness of the powder grains, which can be as small as 20 micrometres, or 0.0008 inch) over the bed where the part is being built up. In MIT’s 3DP process this layer is passed over by a device similar to the head of an ink-jet printer. An array of nozzles sprays a binding agent in a pattern determined by the computer program, then a fresh layer of powder is spread over the entire build-up area, and the process is repeated. At each repetition the build-up bed is lowered by precisely the thickness of the new layer of powder. When the process is complete, the built-up part, embedded in unconsolidated powder, is pulled out, cleaned, and sometimes put through some post-processing finishing steps.

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