Abstract: A method and apparatus for forming a three-dimensional article includes dispensing build material and thermally normalizing predetermined portions thereof at predetermined intervals during construction of the article. The thermal energy may be provided by a heated body advanced adjacent to or in contact with the surface portions. Thermal energy may also be supplied by a radiation source. The thermal normalization may be performed after a predetermined number of successive layers are dispensed. Related methods are also disclosed.

Abstract: A three-dimensional article making apparatus includes a build material dispenser for dispensing build material based upon the article defining data, and a deviation sensor for sensing a deviation during construction of the article. The apparatus may operate the build material dispensing means to adjust or recover for a sensed deviation during construction of the article. A portion of dispensed build material may be removed responsive to a sensed deviation. In addition, the deviation sensor may be operated a plurality of times during construction of the article, and a portion of dispensed build material may be removed down to a previous desired article portion. The deviation sensor may be provided by article formation deviation sensor, a build material dispenser sensor, an article defining data deviation sensor, and/or a build rate deviation sensor. The article deviation sensor may cooperate with a heated electrically conductive body used to periodically dimensionally normalize the article.

Abstract: A three-dimensional article making apparatus includes a first positioner for positioning a build material jetting head along a first direction, a second positioner for positioning the first positioner along a second direction so that the jetting head is effectively positionable along the second direction as well, and a build material reservoir being mounted on the first positioner so that a flexible connecting tube need only flex to accommodate positioning of jetting head along the first direction but not along the second direction. The jetting head may be a piezoelectric jet which operates by forming a negative meniscus at an orifice of jet between droplets. Accordingly, the build material reservoir may be mounted vertically relative to the piezoelectric jet to form the negative meniscus by negative head pressure. The apparatus preferably includes a solid build material supply mounted on an apparatus frame for storing build material in solid form.

Abstract: A three-dimensional article making apparatus includes a build material dispenser positioned adjacent a platform for ejecting a plurality of droplets of build material; and dispenser positioners for relatively positioning the dispenser in five degrees of freedom with respect to the platform. Accordingly, the dispenser may be rotated and flipped to permit construction of a cantilevered portion of an article without requiring support material. The dispenser positioners include a Z-direction positioner for positioning the dispenser vertically relative to the platform, an X-Y positioner for positioning the dispenser in an X-Y planar direction relative to the platform, a flip angle positioner for rotatably positioning the dispenser relative to a generally horizontal axis, and a phi angle positioner for rotatably positioning the dispenser relative to a generally vertical axis.

Abstract: An apparatus for making a three-dimensional article based upon article defining data may be used to make a mold for the article and molding the article from the mold. Alternately, the apparatus may be used to make articles having filled or solid portions. The apparatus preferably includes a base, a processor for defining a mold skin for producing a mold for the three-dimensional article, and a build material dispenser for dispensing build material responsive to the processor to construct the mold skin extending outwardly from the base and defining at least one cavity. Solidifiable fill material is introduced into the cavity to form solid mold portions. The solid mold portions may be separated from the mold skin, and injection molding, for example, used to mold the three-dimensional article. The base preferably includes a thin plastic layer which is penetrable to permit introduction of the solidifiable fill material into the cavity.

Abstract: A three-dimensional article making apparatus includes a processor operatively connected to a dispenser and positioner for constructing the article based upon the article defining data. The processor operates the dispenser to construct an enlarged surface of a first article portion to thereby define an enhanced target landing point area for dispensed droplets of build material for constructing a second article portion adjacent the first article portion. The enhanced target landing point area permits a slight misalignment or error that may occur between adjacent article portions. The processor also avoids shadowing during construction of the article by operating the dispenser to construct third and fourth adjacent article portions so that a dispensing path for constructing the third article portion is unobstructed by a previously constructed part of the fourth article portion. Related methods are also disclosed.

Abstract: A method and apparatus for forming a three-dimensional article includes dispensing build material and thermally normalizing predetermined portions thereof at predetermined intervals during construction of the article. The thermal energy may be provided by a heated body advanced adjacent to or in contact with the surface portions. Thermal energy may also be supplied by a radiation source. The thermal normalization may be performed after a predetermined number of successive layers are dispensed. Related methods are also disclosed.

Abstract: An apparatus includes a processor for controlling a build material dispenser and a dispenser positioner to construct a three-dimensional article in successive layers based upon article defining data, and wherein the processor operates the dispenser to dispense a series of bursts of build material at a series of respective target positions as the dispenser is advanced along a predetermined path of travel. Each burst is defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position. The build material dispenser is preferably a jet including a piezoelectric actuator for ejecting a droplet of build material responsive to a corresponding firing signal. Accordingly, the processor generates a predetermined number of firing signals for the piezoelectric actuator corresponding to a desired number of droplets in each burst. Method aspects of the invention are also disclosed.