Abstract: An electroplating method that includes: a) contacting a first substrate with a first article, which includes a substrate and a conformable mask disposed in a pattern on the substrate; b) electroplating a first metal from a source of metal ions onto the first substrate in a first pattern, the first pattern corresponding to the complement of the conformable mask pattern; and c) removing the first article from the first substrate, is disclosed. Electroplating articles and electroplating apparatus are also disclosed.

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: Tool having a molding surface is formed from a flowable material (e.g., powder material) wherein the shape of molding surface is formed from a molding process using a master pattern having a surface with a shape substantially the same as the shape of the molding surface to be formed. The tool has at least one thermal control element located within it and spaced from the molding surface where a component used in forming the thermal control element is located within the flowable material prior to solidifying the material. The powder material is preferably a mixture of metals. The thermal control elements include fluid flow paths, heating elements, temperature sensors, and the like.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for producing three-dimensional objects by selectively subjecting a liquid or other fluid-like material to a beam of prescribed stimulation. In a preferred embodiment a source of prescribed stimulation is controlled to reduce or inhibit the production of the prescribed stimulation during at least some periods when the prescribed stimulation is not needed to expose the material. In another preferred embodiment, the source of stimulation is controlled to vary the quantity of prescribed stimulation that is produced and allowed to reach the material. In an additional preferred embodiment control of laser output occurs based on a combination of supplying a regulated amount of voltage to an AOM in conjunction with temporary sensing of laser power and a known desired power to attain.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects with enhanced control of coating parameters used when forming layers of liquid or other fluid-like material in preparation for forming laminae of the object. The each lamina of the object is treated as either a primary laminae or secondary laminae. Only minority portions of the secondary layers are solidified when their associated layers are formed. Primary laminae are solidified in majority portions, along with previously unsolidified portions of secondary lamina, when their associated layers are formed. Recoating parameters are supplied for groups of primary layers and secondary layers such that coating formation may be controlled differently for primary layers and for secondary layers. Coating control for secondary layers may be based on the position of individual secondary layers, or sets of secondary layers, relative to the primary layers.

Abstract: Embodiments of the instant invention are directed to various methods and an apparatus for building a three-dimensional object represented by object data and support data using thermal stereolithography. Some preferred embodiments of the building techniques include multiple building materials, wherein, in some preferred embodiments, a different building material is used to build the object and the support. Embodiments of the methods for building three-dimensional objects include manipulation of the data, which is represented by a plurality of start/stop transitions to facilitate the computation of Boolean operations. In preferred embodiments, the object is built by selective disposition of the building materials in accordance with the object and support data.

Abstract: An apparatus for producing an object by stereolithography is provided with a tank (1) receiving a bath of liquid or powdery material which can be solidified by action of electromagnetic radiation. In known manner the apparatus comprises a support (4) for positioning the object relative to the surface (3) of the bath and a device (8) for solidifying a layer of the material (3) adjacent to the surface using electromagnetic radiation. In order to allow a precise adjustment of the layer thickness the apparatus comprises a supplying device (51) for supplying the solidifiable material (3), the supplying device extending transversely across the tank and having a discharge opening (53) at its bottom side in operational position, a channel extending in the interior thereof and communicating with the discharge opening (53), the channel being connected at one point with a pump (63) through a conduit (62).

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: A method of and apparatus for slicing a three-dimensional object representation into a plurality of layer representations is described, wherein the layer representations are subsequently used to form the object layer-by-layer according to the principles of stereolithography. If not already provided in the object representation, a plurality of layer boundary representations are first formed, and then the boolean difference of successive layer boundary representations are computed to derive boundaries of up and down-facing regions, enabling different cure parameters to be specified for these different regions.