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 by-product waste material removal system for solid deposition modeling. As excess build and support material is removed during the build as a by-product waste the removal system accumulates, measures, and releases the by-product waste material into a waste receptacle for disposal. The by-product waste material removal system requires no mechanical vacuum systems and allows operator intervention to remove and replace waste receptacles without interrupting an ongoing build.

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 liquid radiation-curable composition that comprises (A) at least one polymerizing organic substance comprising a mixture of (1) at least one alicyclic epoxide having at least two epoxy groups; and (2) at least one difunctional or higher functional glycidylether of a polyhydric compound; (B) at least one free-radical polymerizing organic substance comprising a mixture of (1) optionally, at least one trifunctional or higher functional (meth)acrylate compound; and (2) at least one aromatic di(meth)acrylate compound; (C) at least one cationic polymerization initiator; (D) at least one free-radical polymerization initiator; (E) optionally, at least one hydroxyl-functional aliphatic compound; and (F) at least one hydroxyl-functional aromatic compound; wherein the concentration of hydroxyl groups in the radiation-curable composition is at least about 1.1 equivalent OH groups per kilogram; wherein the concentration of epoxy groups in the radiation-curable composition is at least about 5.

Abstract: The present invention relates to a paste composition, including a bonding agent charged with a metallic powder, to be used in a prototyping procedure, a procedure for obtaining metallic products from said composition, and a metallic product obtained from said procedure. The composition is characterized by the fact that it includes: a bonding agent comprised of at least one photopolymerizable resin, with a viscosity of less than 4000 mPa.s, measured at 25° C., a photoinitiator, in a concentration greater than 0.2% by mass with respect to the mass of the resin, and a metallic powder in a volumetric concentration greater than 40% with respect to the composition, with said composition having a minimum reactivity on the order of 5 mm3/s per watt of lighting power.

Abstract: An apparatus and a method of using the apparatus wherein a radiation emitter is positioned adjacent a sensor apparatus within a process chamber in a laser sinter system that emits radiation to the sensor apparatus and a calibration apparatus receives readings from the sensor apparatus to compare temperature sensings received from the sensor apparatus with set emission signals from the radiation emitter to adjust the temperature sensings to calibrate the sensor apparatus during the forming of a three-dimensional article. The calibration is done repeatedly during the build process of the three-dimensional article.

Abstract: A material feed system for solid freeform fabrication. The build material is delivered in discrete or quantized amounts by the feed system in a non-flowable state to the dispensing device and the material is then changed to a flowable state prior to being dispensed. The feed system can be used to build three-dimensional objects in color, if desired. In one embodiment individual cartridges with build material are loaded into a magazine on the feed system which is integrated with a waste removal system. As the build material is expelled from the cartridges, waste material is deposited into the cartridge. Once all the build material has been expelled, the waste material is hermetically sealed in the spent cartridge which is then ejected from the system. The hermetically sealed cartridges protect operators from contact with the reactive waste material making the system safe for the office environment.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder, a wetting agent, and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous preform structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The wetting agent assists in wetting during infiltration. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A liquid radiation-curable composition that comprises (A) at least one polymerizing organic substance; (B) at least one free-radical polymerizing organic substance; (C) at least one cationic polymerization initiator; (D) at least one free-radical polymerization initiator; (E) at least one hydroxyl-functional compound; and (F) at least one epoxy interpenetrating polymer compound;

Abstract: A powder blend for use in laser sintering and a method for forming tough, strong, wear-resistant, corrosion-resistant infiltrated metal products are provided. The powder blend comprises a steel alloy, a polymeric binder and a high melting temperature fine particulate which are blended together, then applied layer by layer to a working surface in a laser sintering system, exposed a layer at a time to fuse together the powder until a green part of high strength is formed, and then the green part is infiltrated with a metal infiltrant in a non-reducing gas atmosphere at an effective temperature for an effective period of time. The preferred steel is a mild steel alloy.

Abstract: A method and apparatus for forming three dimensional objects by laser sintering that utilizes a broad area thermal vision system such as an infrared camera that can measure multiple temperatures across the target area and use that temperature data as feed back to a control system that both adjusts a zoned radiant heater system and adjusts scan speed and laser power to control temperatures across the target area.

Abstract: A solid freeform fabrication method and apparatus for making objects in a layer by layer manner in which the objects have special geometrical features requiring specialized control parameters. The method and apparatus automatically determines and selects the build parameters for the build process based on automatic part feature recognition. A general build style is first determined having a plurality of default parameters for building the object. Data representing the object is imported and oriented with a Z-axis. The data is then processed by slicing software that automatically identifies special build types for specific ranges of Z-values and selects the alternative parameters needed to successfully build these features. Preferably a look-up table contains special sets of values for the parameters for each special build type possible in which the slicing algorithm can select from. During slicing, operator intervention is not needed to prepare all the parameters necessary for a successful build.

Abstract: An improved stereolithographic process for forming three-dimensional objects using an improved support structure and the improved support structure is described. 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: An improved enhancer formulation for use in forming precision molded articles from a furnace process is disclosed wherein an organometallic zirconia coupling agent is used in conjunction with a polymer in solvent to inhibit the bleed-through of infiltrant metal in a finished part formed in a single-step furnace process.

Abstract: A selective deposition modeling apparatus utilizing a planarizer to dimensionally normalize the layers of a three-dimensional object as it is being built. The apparatus includes a means for measuring the power used to dimensionally normalize the layers which is indicative of the amount of excess build material that has been dispensed. The apparatus then utilizes the measurement to alter the excess amount of build material of a next dispensed layer so as to optimize the build rate and reduce the production of waste material. In one embodiment the planarizer is rotated at a constant angular velocity by a motor and the current supplied to the motor is monitored, and a print head supplied with a firing voltage is used to dispense the build material. The voltage supplied to the print head is adjusted to optimize the build rate of the apparatus.

Abstract: The invention concerns a fast three-dimensional modeling method comprising the following steps: a phase which consists in transforming the raw material in the work space (32) by means of a device inducing transformation (1); at least at one moment, a phase which consists in supplying non-transformed material, downstream of the doctor blade; a phase which consists in covering the transformed material (PI) with non-transformed material (MAT), which consists in moving the blade in a direction (F), driving in rotation about an axis a rolling member (26, 27) whereon an extruded log of non-transformed raw material (28) is wound, arranging a pushing member (22) such that its proximal edge (23) coincides with the surface of said work space, and positioning said rolling member downstream of the pushing member, and opposite thereof, so as to channel the extruded log of non-tramsformed material towards a cavity formed between the proximal edge and the rolling member facing it.

Abstract: A method for removing supports from a three-dimensional objected formed by selective deposition modeling. The three-dimensional object is formed from a curable phase change material and the supports are formed from a non-curable phase change material. The curable phase change material contains between about 5% to about 25% of a non-reactive wax in order to achieve the desired phase change characteristics of the material. When removing the supports with heat, discoloration undesirably occurs in the three-dimensional object as the non-reactive wax migrates within the object. The method prevents wax migration by cooling the object slowly past the freezing point of the build material such that a temperature differential no greater than about 5° C. is present within the object. With the preferred build material having a freezing point of about 49.5° C., this is achieved by lowering the temperature between about 62° C. to about 52° C.

Abstract: A method for processing a three-dimensional object formed by solid freeform fabrication from a build material having a polymer component to alter the appearance of the object. A fluid medium carrying an infiltration agent is applied to the object at a temperature above the glass transition temperature of the polymer component for a desired period of time wherein the infiltration agent penetrates the three-dimensional object. The infiltration agent can be a dye that can alter the color of the object.