Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.

Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.

Abstract: A paste composition, including a binding agent charged with metallic powder, to be used in a solid freeform fabrication procedure, comprising: a) a solidifiable binding agent comprised of at least one polymerizable resin, with a viscosity of less than 4000 mPa.s, measured at 25° C.; b) at least one initiator, in a concentration greater than about 0.1% by mass with respect to the mass of the resin; and c) a mixture of at least two metallic powders, said mixture having a volumetric concentration greater than 40% with respect to the composition, wherein said mixture of metal powders is either i) a bimodal or trimodal mixture in nature, or ii) is a majority of stainless steel with an amount of NiB or NiP and combinations thereof effective to lower the sintering temperature.