Abstract: A flash curing system for solid freeform fabrication which generates a plurality of radiation emitting pulses that forms a planar flash. The planar flash initiates curing of a curable material dispensed by a solid freeform fabrication apparatus. The radiation emitting pulses have a high peak power value that releases a sufficient quantity of free radicals from the photoinitiator to initiate curing and overcome the problem of oxygen inhibition. Substantially less power is consumed and less heat generated by the flash curing system compared to conventional continuous emission curing systems.

Abstract: A cooling system for removing heat from the layers of a three-dimensional object built in a layerwise manner from a build material in a solid freeform fabrication apparatus. The cooling system provides an air duct that delivers a uniform sheet of air flow over the layers of the three-dimensional object while it is built. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Abstract: A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.

Abstract: A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.

Abstract: A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.

Abstract: A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.

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 collects the by-product waste material into a waste receptacle for disposal. The by-product waste material removal system requires no mechanical systems.

Abstract: A jettable non-curable support material composition useful for three-dimensional ink jet printing comprising at least one fatty alcohol and at least one abietic rosin ester alcohol, wherein the support material has a melting point between about 50° C. to about 65° C. and a freezing point between about 45° C. to about 55° C.

Abstract: A method and apparatus for effectively removing gas bubbles in systems fed to ink-jetting devices. The system removes both small and large-scale gas bubbles from systems that feed materials to ink jet print heads.

Abstract: A post processing apparatus for automated removal of support material from a three-dimensional objected formed from a build material by selective deposition modeling is provided. The apparatus includes a heated main chamber into which is placed the three-dimensional object with the support material attached and first and second liquid heat transfer medium storage reservoirs. The storage reservoirs reversibly provide liquid heat transfer medium to the main chamber to immerse the three-dimensional object and the attached support material for desired periods of time to meltingly separate the support material from 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: 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: The invention relates to a method producing parts using laser sintering wherein a fusible powder is exposed to a plurality of laser scans at controlled energy levels and for time periods to melt and densify the powder and in the substantial absence of particle bonding outside the fusion boundary. Strength is improved up to 100% compared to previous methods. An example includes a relatively high energy initial scan to melt the powder followed by lower energy scans controlled to densify the melt and separated in time to dissipate heat to the surrounding part cake. The rate and extent to which the powder particles are fused together can be controlled so that each successive scan can be used to fuse the particles together in discreet incremental steps. As a result, the final dimensions of the part and its density and mechanical properties can be improved compared to conventional methods and part growth avoided.

Abstract: A convection cooling technique for selective deposition modeling utilizing a venturi duct to establish a low-pressure port for drawing a second flow of air into the duct. The second flow of air is drawn across a heat generating component in the selective deposition modeling apparatus. A low-pressure zone is established at the low-pressure port sufficient to meet the head loss that results when drawing the second flow across the heat generating component and into the venturi duct. A desired flow rate is achieved at a pressure drop that is greater than that possible by the direct use of a fan. The cooling system is well suited for use in providing steady state cooling of radiation exposure systems used in selective deposition modeling to initiate curing of the layers of dispensed material.

Abstract: A cooling system for removing heat from the layers of a three-dimensional object built in a layerwise manner from a build material in a solid freeform fabrication apparatus. The cooling system provides an air duct that delivers a uniform sheet of air flow over the layers of the three-dimensional object while it is built. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Abstract: A ventilation and cooling system for a selective deposition modeling apparatus dispensing a curable material. The ventilation and cooling system captures airborne contaminants in the apparatus making the apparatus suitable for use in an office environment. A pressure drop is established within the apparatus to assure that all air that enters the apparatus passes through a filter which captures the airborne contaminants before the air is expelled from the apparatus. Sensors are provided to assure that the ventilation and cooling system is function properly, and if not, the apparatus is either shut down or a signal is provided to the operator indicating that the system is not functioning properly.

Abstract: A support structure is applied directly to the first side of a semiconductor work piece or wafer by a stereolithographic process layer by layer completely about and extending inwardly of the periphery of the wafer, but external to the selected area within which a desired circuitry pattern is placed, the support structure being of a desired height and of a material resistive to an acid etch process effective to seal the circuitry pattern in the selected area from acid when the work piece is subjected to an acid etch on the opposing second side and about the periphery. The support structure further strengthens the work piece against flexural failure.

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 laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 ?m, provided further that the number average ratio of particles smaller than 53 ?m is greater than 80%, the remaining larger particles being in the size range from 53 ?m to 180 ?m. A powder with slow recrystallization rates, as evidenced by non-overlapping or slightly overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10° C. to 20° C.