Abstract: A power management system for a selective deposition modeling apparatus for maintaining the power consumption of the apparatus within the limits of conventional power available in most all office environments. The apparatus has a plurality of power drawing components, each component having a activation power rating wherein the accumulative total of all the power ratings exceeds a baseline power consumption value for the apparatus. The system prevents a baseline power consumption value from being exceeded by determining which components can be activated while leaving others inactivated.

Abstract: A method of forming a three-dimensional object in layerwise fashion by selectively solidifying a build material. The method solidifies the main part area, delays or pauses for a desired period of time to permit shrinkage to occur, and then, in multiple drawings of the main part borders, solidifies the borders from the portion closest to the main part outwardly to the portion farthest from the main part.

Abstract: A computer-controlled apparatus and method for fabricating three-dimensional articles in layerwise fashion is disclosed. Upon dispensing a layer of a fusible powder, a laser irradiates selected locations of that layer to fuse the powder into a cross-section of the article to be formed in that layer, such that the fused cross-sections fuse together into the article. The laser is controlled in a raster scan fashion across the selected locations of the powder layer. The parallel raster scan lines are separated from one another, centerline-to-centerline, according to a selected pitch, or fill scan spacing value. The positions of the parallel scan lines are determined with respect to a coordinate system at the powder layer, rather than with respect to boundaries of the cross-section being formed; in alternating layers, the parallel scan lines are offset from one another by one-half the pitch.

Abstract: An improved slicing technique is disclosed that employs micro-slicing or intermediate slices by identifying intermediate triangle vertices in the STL data and passing slice layers through each intermediate vertex to create a final build object or part that has smoother contouring, greater accuracy and an improved surface appearance than parts obtained using prior slicing methods.

Abstract: A computer-controlled apparatus and method for fabricating three-dimensional articles in layerwise fashion is disclosed. Upon dispensing a layer of a fusible powder, a laser irradiates selected locations of that layer to fuse the powder into a cross-section of the article to be formed in that layer, such that the fused cross-sections fuse together into the article. The laser is controlled in a raster scan fashion across the selected locations of the powder layer. The raster scan lines are defined, for each cross-section, to achieve an optimal fill scan time. The optimal fill scan time is determined, by the computer estimating the fill scan time by rotating the cross-section over a plurality of rotational angles, and estimating the fill scan time for each of the rotated cross-sections for at least a sample of the fill scans necessary to form the article.

Abstract: A detoxification process for rendering three-dimensional objects formed by solid freeform fabrication techniques biocompatible for use in long-term dermal contact applications. The process nullifies cytotoxins normally present in objects formed by solid freeform fabrication techniques rendering such techniques as viable for the production of biocompatible devices such as stents, artery valve components, bone implant supports, pacemaker shells, surgical tools, and the like. In one embodiment, a custom hearing aid shell is produced by stereolithography from an acrylate photopolymer resin that was detoxified for long-term dermal contact application. The detoxification process makes three-dimensional objects created by solid freeform fabrication techniques available for products requiring biocompatibility.

Abstract: A variety of support structures and build styles for use in Rapid Prototyping and Manufacturing systems are described wherein particular emphasis is given to Thermal Stereolithography, Fused Deposition Modeling, and Selective Deposition Modeling systems, and wherein a 3D modeling system is presented which uses multijet dispensing and a single material for both object and support formation.

Abstract: A method of applying highly viscous paste-like build materials in layers in a solid freeform fabrication apparatus to form three-dimensional objects. A viscosity modifier is first introduced into the build material to establish a low viscosity state and then the material is dispensed in layers on a working surface. The viscosity modifier is then removed from the build material preferably by evaporation, and the layer is selectively solidified to form the three-dimensional object. The method substantially eliminates the undesirable effects of induced shear stress imposed on lower layers when attempting to apply uniform layers of highly viscous materials in solid freeform fabrication techniques. The method allows for the use of highly viscous paste-like materials that can include upwards of 50% by weight of metallic, ceramic, mineral, or polymer powders. Preferably the binder is a photocurable resin or thermocurable material which is selectively solidified to form the three-dimensional objects.

Abstract: A method of forming a three-dimensional object in layerwise fashion by selectively solidifying a build material in a reinforced cyclical fashion. The method solidifies a first fully cured layer of build material and then partially solidifies at least one partially cured intermediate layer of build material having areas of liquid build material and areas of solidifying build material. The method repeats the cycle by solidifying a next overlying fully cured layer of build material and also the underlying liquid areas of build material in the at least one partially cured intermediate layer of build material.

Abstract: A paste composition, including a binding agent charged with metallic powder, to be used in a solid freeform fabrication procedure, comprising: a) a solidifiable binding agent comprised of at least one polymerizable resin, with a viscosity of less than 4000 mPa.s, measured at 25° C.; b) at least one initiator, in a concentration greater than about 0.1% by mass with respect to the mass of the resin; and c) a mixture of at least two metallic powders, said mixture having a volumetric concentration greater than 40% with respect to the composition, wherein said mixture of metal powders is either i) a bimodal or trimodal mixture in nature, or ii) is a majority of stainless steel with an amount of NiB or NiP and combinations thereof effective to lower the sintering temperature.

Abstract: Rapid prototyping and manufacturing (e.g. stereolithography) methods and apparatus are disclosed that form objects with enhanced accuracy and small feature retention. Techniques for offsetting cross-sectional boundary data to at least partially accommodate for solidification width induced in a medium by a beam of radiation are provided. One technique uses repeated small offsets to yield an effective offset of a desired amount. A second technique uses displacement vectors to determine where and to what extent to offset the boundary segments. The offset amount for each vertex is determined based on a combination of the (1) the vertex angle, and (2) a predefined variable offset criteria which is different for at least two predefined ranges of angles. A third technique converts a single boundary segments into a plurality of offset boundary segments when the single boundary segment can not undergo the full desired offset without violating another offsetting rule.

Abstract: An improved stereolithography system for generating a three-dimensional object by creating a cross-sectional pattern of the object to be formed at a selected surface of a fluid medium capable of altering its physical state in response to appropriate synergistic stimulation by impinging radiation, particle bombardment or chemical reaction, information defining the object being specially processed to reduce curl and distortion, and increase resolution, strength, accuracy, speed and economy of reproduction even for rather difficult object shapes, the successive adjacent laminae, representing corresponding successive adjacent cross-sections of the object, being automatically formed and integrated together to provide a step-wise laminar buildup of the desired object, whereby a three-dimensional object is formed and drawn from a substantially planar surface of the fluid medium during the forming process.

Abstract: An improved process for forming photocurable three-dimensional objects using an improved curing process is disclosed. The build object is formed by using differential curing of the photocurable media material to form cured solid regions with discrete mechanical properties at selected locations to tailor a part's properties to individual needs.

Abstract: An improved selective deposition modeling method which produces a cold weld joint in an object formed by dispensing a single phase change material. The cold weld joint can be controlled so that a lower portion of the object can serve as a support structure for forming the upper portion of the object. Upon separation of the lower and upper portions along the cold weld joint, a downward facing surface is revealed on the upper portion exhibiting superior detail and quality compared to other downward facing surfaces created by conventional selective deposition modeling techniques. The method can readily be adapted for use by selective deposition modeling machines utilizing ink jet print heads dispensing a single phase change material.

Abstract: An improved layer normalizing device for use in dimensionally normalizing layers of a three-dimensional model produced by a selective deposition modeling technique. The layer normalizing device employs a wicking member having a body and a normalizing surface for dimensionally normalizing the object while the object is being built layer by layer. The body includes a plurality of interstices, and when the wicking member is sufficiently heated to cause the build material to become flowable, excess material is drawn by capillary action from the layer of the object being normalized and into the wicking member. A refreshing means is provided to remove the excess build material from the interstices of the wicking member and allow the wicking member to draw additional build material by capillary action.

Abstract: An improved stereolithographic process for forming three-dimensional objects using an improved support structure. The support structure is formed by using differential curing of the liquid media material to form solid supports with weak points at selected locations to facilitate support removal from a three-dimensional object and minimize post-processing.

Abstract: Solid state lasers that use non-linear optical crystals to generate frequency tripled or quadrupled output in the ultraviolet have low lifetimes due to damage to the face of the non-linear crystal through which the ultraviolet signal exits. To prevent this damage, the tripling or quadrupling crystal is provided within a controlled environment that is maintained substantially free from contaminants such as silicon-bearing and organic compounds. The tripling or quadrupling crystal is enclosed within a tubular chamber with windows on the ends of the tube that provide optical access to the entrance and exit faces of the tripling or quadrupling crystal. All heating elements and alignment elements for the crystal are outside of the chamber. Because the crystal is stored within the hermetically sealed chamber, contaminants are not available within the environment of the crystal that could interact with the energetic photons of the ultraviolet output of the frequency multiplied solid state laser.

Abstract: A method of manipulating data in a method for forming a three-dimensional object layer by layer from an ink jettable, solidifiable material by providing data corresponding to a plurality of polygons defining the outer surfaces of a plurality of three-demiensional objects and providing sets of x, y, and z coordinates corresponding to each layer and identifying x and y coordinates with each z coordinate such that directional values and counter values are determined for each y coordinate in a first set of coordinates generated. A second set of y coordinates are generated according to a formula that permits the determined layers to be processed to form a three-dimensional object.

Abstract: A solubilizing agent and a compound made by reacting selected nucleophiles, including fatty acid reactants and amines with an isocyanate are disclosed. The addition of the isocyanate and the different nucleophiles will create a di-urethane tetra-amide solubilizing agent product. The polyamide-solubilizing agent is useful as an ingredient in a phase change solid imaging material and as carrier compositions used to make phase change ink jet inks.

Abstract: A variety of support structures and build styles for use in Rapid Prototyping and Manufacturing systems are described wherein particular emphasis is given to Thermal Stereolithography, Fused Deposition Modeling, and Selective Deposition Modeling systems, and wherein a 3D modeling system is presented which uses multijet dispensing and a single material for both object and support formation.