Abstract: Techniques for controlling jobs in a selective deposition modeling (Selective Deposition Modeling) system. A client computer system can connect directly to a Selective Deposition Modeling system to work with a job queue located at the Selective Deposition Modeling system. Jobs in the job queue may be previewed in three-dimensional form. Moreover, the jobs in the job queue may be manipulated to move the jobs to different positions in the job queue or to delete a job. Additionally, multiple jobs may be automatically combined to generate a single build process.

Abstract: An illumination system includes optics capable of adjusting the size of a beam of light and adjusting the focus of the beam of light. Spot size control optics adjusts the overall size of the beam of light and separately adjusts the ellipticity of the beam, primarily in one dimension. Light from the spot size control optics passes to focus control optics that control the overall focus of the beam of light and adjust the astigmatism of the beam by altering the focus position of the beam of light in one dimension. The laser system, the spot size control optics and the focus control optics are within an enclosure. Actuators under remote control from outside of the enclosure adjust both of the spot size control optics and focus control optics in the thermal environment of the illumination system.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects on a layer by layer basis by selectively exposing layers of material to prescribed stimulation, using a beam having a first smaller diameter and a beam having a second larger diameter, to form laminae of the object. The power of the smaller beam is typically lower than the power of the larger beam. Object formation is controlled by data representing portions of the layers to be exposed with the larger beam (large spot portions) and those portions to be exposed with the smaller beam (small spot portions). In a preferred embodiment, portions exposed with the larger beam are formed first, for a given layer. Portions are exposed with the small beam next. Thereafter the entire perimeter of the laminae is traced using the small beam.

Abstract: Phase change compositions that are solid at ambient temperature and liquid at an elevated temperature above ambient temperature are disclosed for advantageous use in selective deposition modeling methods for building three-dimensional objects. A phase change composition according to the disclosed invention is a semi-crystalline component mixture having a freezing point of at least about 68° C., a melting point of at least about 88° C. and a viscosity of about 13 centipoise at 135° C. The composition includes a plurality of waxes having a broad melting point range and molecular weight range. Three-dimensional objects having minimal curl, delamination and stress cracks can be produced at a faster rate than heretofore known by using selective deposition modeling techniques employing the disclosed compositions.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects on a layer-by-layer basis by selectively exposing layers of material to prescribed synergistic stimulation including forming portions of a lamina using a first exposure, allowing a time delay, and then applying a second exposure. The time delay is sufficient to allow shrinkage of the material to occur that results from the first exposure. It is preferred that the solidified portion resulting from the first exposure does not adhere to the previously formed lamina. It is also preferred that the portion solidified by this first exposure does not adhere to any boundary region that may have been exposed and adhered to the previously formed lamina. The time delay associated with a given cross-sectional region may be occupied by exposing other cross-sectional regions. The delay may occur between two exposures of overlaying hatch or fill vectors.

Abstract: A component to control the viscosity of phase change material formulations is made by reacting selected nucleophiles, including fatty acid/alcohol reactants with an isocyanate, is disclosed. The addition of the isocyanate and the different nucleophiles will create a viscosity modifying component of low viscosity that can be formulated with higher molecular weight polyamide resins to achieve increased toughness in phase change solid imaging materials and carrier compositions used to make phase change ink jet inks.

Abstract: A method and apparatus for making high resolution objects by stereolithography utilizing low resolution materials which are limited by their inability to form unsupported structures of desired thinness and/or their inability to form coatings of desired thinness. Data manipulation techniques, based on layer comparisons, are used to control exposure in order to delay solidification of the material on at least portions of at least some cross-sections until higher layers of material are deposited so as to allow down-facing features of the object to be located at a depth in the building material which is equal to or exceeds a minimum cure depth that can effectively be used for solidifying these features. Similar data manipulations are used to ensure minimum reliable coating thicknesses exist, above previously solidified material, before attempting solidification of a next layer. In addition, horizontal comparison techniques are used to provide enhanced cross-sectional data for use in forming the object.

Abstract: Rapid prototyping modeling typically operates by utilizing an ink jet to lay down a thin surface of material as a liquid on a part platform. The material solidifies into a three dimensional object. Computer programs determine the shape of the object, the arrangement of objects and the sequence of objects being built to protect parts of the planarizer roller and planarizer blade of a rapid prototyping machine from erosion.

Abstract: A solid state laser includes a high absorption coefficient solid state gain medium such as Nd:YVO4 that is side pumped with a semiconductor laser diode array. The resonant cavity of the solid state laser is positioned so that the TEM00 mode is spaced from the face of the laser through which the laser is pumped by a distance sufficient to reduce diffraction losses but sufficiently near to allow coupling of pump light into the gain mode. The gain medium, the doping level of the gain medium, and the operating temperature of the pump laser are selected to efficiently couple pump light into the gain mode. The pump laser is positioned to side pump the gain medium without collimating or focusing optics between the pump laser and the face of the gain medium. A gap between the pump laser and the gain medium is empirically selected to match the angular extent of the pump laser output light to the height of the gain mode at the position of the gain mode fixed to optimize coupling and diffraction losses.

Abstract: A method, system and apparatus for forming a three-dimensional object on a layer-by-layer basis involves forming a portion of the three-dimensional object using selective deposition modeling (SDM). SDM involves using at least one orifice, such as a jet, which dispenses a droplet of a flowable material that solidifies upon being dispensed. A drop volume capability of each orifice is adjusted until substantially all orifices have a uniform drop volume capability and all dispensed droplets of the flowable material have a uniform volume.

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.

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 system and associated method for forming three-dimensional objects under computer control and from a material which may be rendered flowable and then dispensed on a layer-by-layer basis. The layers of the material solidify or otherwise physically transform upon being dispensed thereby forming successive cross-sections. The dispensing process is repeated whereby successive layers adhere to each other thereby forming the object.

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: An improved method for stereolithographically making an object by alternating the order in which similar sets of vectors are exposed over two or more layers. In another method, a pattern of tightly packed hexagonal tiles are drawn. Each tile is isolated from its neighboring tiles by specifying breaks of unexposed material between the tiles. Using an interrupted scan method, vectors are drawn with periodic breaks along their lengths. In another method, modulator and scanning techniques are used to reduce exposure problems associated with the acceleration and deceleration of the scanning system when jumping between vectors or changing scanning directions. In another method, a capability for automatically inserting vents an drains into a three-dimensional object representation is provided.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) apparatus includes a secondary frame located within a primary frame of the system. The secondary frame defines an enclosure for housing a number of peripheral heat-producing components and peripheral vibration-producing components. The heat generated by these peripheral heat-producing components is substantially isolated in the enclosure and is removed from the primary frame so as not to cause an undesired impact on other components within the main frame. The secondary frame preferably sits directly on the floor or other surface without touching the primary frame, thus substantially avoiding transmittance of vibration from components in the enclosure to the primary frame of the system.

Abstract: A method and apparatus for building three-dimensional objects having an internal structure, wherein the structure is discontinuous and is composed from a plurality of patterns and bridging patterns formed on a plurality of levels, wherein a bridging level and pattern reside between previous and subsequent levels from which the bridging pattern obtains at least a portion of its pattern. A portion of the bridging pattern is obtained from the pattern on the previous level and a portion of the bridging pattern is obtained from the pattern on the subsequent level.

Abstract: An improved method for stereolithographically making an object by alternating the order in which similar sets of vectors are exposed over two or more layers. In another method, a pattern of tightly packed hexagonal tiles are drawn. Each tile is isolated from its neighboring tiles by specifying breaks of unexposed material between the tiles. Using an interrupted scan method, vectors are drawn with periodic breaks along their lengths. In another method, modulator and scanning techniques are used to reduce exposure problems associated with the acceleration and deceleration of the scanning system when jumping between vectors or changing scanning directions. In another method, a capability for automatically inserting vents an drains into a three-dimensional object representation is provided.

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: 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.