Abstract: A computer controlled additive manufacturing process in which a non-polymer material and a non-polymer liquid binder are combined to form a paste that is extruded into the volume enclosed by the target model after which a laser beam of sufficient energy is guided along the same extrusion path to remove some portion of liquid binder, transition the material from paste form into solid form, and/or bond the material to surrounding material.

Abstract: A self-configuring computer-controlled fabrication apparatus that utilizes no fewer than four user changeable tools concurrently installed to fabricate a three-dimensional component from digital design data out of a variety of materials using additive and/or subtractive methods. User interchangeable tools perform different tasks including paste extrusion, filament extrusion, inkjet deposition, laser curing, laser etching, milling, cooling, curing, inspection, and component placement, among others. Each tool, that is selected and installed by the user for each job, contains operational information regarding its performance in nonvolatile memory such that the system can read, then adapt, the build process to the set of tools currently installed.

Abstract: A computer controlled additive manufacturing process in which a non-polymer material and a non-polymer liquid binder are combined to form a paste that is extruded into the volume enclosed by the target model after which a laser beam of sufficient energy is guided along the same extrusion path to remove some portion of liquid binder, transition the material from paste form into solid form, and/or bond the material to surrounding material.

Abstract: A self-configuring computer-controlled fabrication apparatus that utilizes no fewer than four user changeable tools concurrently installed to fabricate a three-dimensional component from digital design data out of a variety of materials using additive and/or subtractive methods. User interchangeable tools perform different tasks including paste extrusion, filament extrusion, inkjet deposition, laser curing, laser etching, milling, cooling, curing, inspection, and component placement, among others. Each tool, that is selected and installed by the user for each job, contains operational information regarding its performance in nonvolatile memory such that the system can read, then adapt, the build process to the set of tools currently installed.

Abstract: A contact coating device comprising a high viscosity rapid deposition head comprising a deposition body defining a material supply passage; a dispensing/shaping nozzle being formed adjacent in a leading end surface of the high viscosity rapid deposition head for dispensing of the high viscosity material from the high viscosity rapid deposition head, and the dispensing/shaping nozzle comprising a dispensing cavity; at least one dispensing passage providing communication between the material supply passage and the dispensing/shaping nozzle for suppling the high viscosity material to the dispensing cavity; and a heating element for heating a portion of the high viscosity rapid deposition and facilitating flow of the high viscosity material through the high viscosity rapid deposition head. A multi-head material deposition system which comprises a first drop-on-demand device, a second drop-on-demand device and at least one contact coating rapid deposition head is also disclosed.

Abstract: A contact coating device comprising a high viscosity rapid deposition head comprising a deposition body defining a material supply passage; a dispensing/shaping nozzle being formed adjacent in a leading end surface of the high viscosity rapid deposition head for dispensing of the high viscosity material from the high viscosity rapid deposition head, and the dispensing/shaping nozzle comprising a dispensing cavity; at least one dispensing passage providing communication between the material supply passage and the dispensing/shaping nozzle for suppling the high viscosity material to the dispensing cavity; and a heating element for heating a portion of the high viscosity rapid deposition and facilitating flow of the high viscosity material through the high viscosity rapid deposition head. A multi-head material deposition system which comprises a first drop-on-demand device, a second drop-on-demand device and at least one contact coating rapid deposition head is also disclosed.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrificial mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.

Abstract: A method for fabricating a three dimensional model by fabricating a composite model formed of a plurality of successive layers comprised of one or more materials wherein each successive layer is formed by depositing at least first material delineating boundaries of at least one first area of the layer by a drop-by-drop deposition and depositing at least a second material over the layer by a rapid deposition method, and may include the deposition of a third material by a drop-by-drop or rapid deposition method and will include planing the layer to a uniform thickness and selectively removing the first and second materials, and third material if present, by successive removal methods, each of which effects only one of the materials.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.