Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Abstract: The present invention is a method for forming an object, the method comprising jetting a first material to form a plurality of layers that define a support structure increment, and extruding a second material to form a layer of the object. The layer of the object substantially conforms to an interior surface of the support structure increment.

Abstract: A cassette for use in delivering a continuous length of filament provides improved reliability by employing means for preventing tangling of the filament in the cassette. The cassette has a substantially closed housing defining a chamber in which a spool is rotatably mounted, and a path from the chamber to an exit orifice. A length of filament is wound around the spool and has a free strand positioned in the path. The filament strand is advanced along the path and delivered through the exit orifice by a means for advancing. Tangling is prevented by locking the spool during transport of the cassette to maintain a tight wind, and by guiding the filament strand along a snag-free path as it is withdrawn from the cassette. In the exemplary embodiments, a removable pin locks a flange or hub of the spool, and the filament strand is withdrawn through a tubular guide member.

Abstract: A multi-tip extrusion method and apparatus for building a three-dimensional object deposits modeling materials from distinct supply sources, each in a layerwise predetermined pattern, from dispensers having co-planar dispensing tips. The tip spacing is controlled so that a road of material extruded by a leading one of the tips will cool and shrink from the plane of the tips before a trailing one of the tips passes over the road. In this manner, smearing of the road by a trailing one of the tips is avoided.

Abstract: Disclosed is a method for making a prototype plastic injection molded part from a mold tool (10) built by fused deposition modeling. The mold too (10)l is built by depositing roads of a molten thermoplastic resin in layers in a predetermined pattern defined by computer file data representing the inverse of the desired prototype molded part, and is used in an injection molding machine without the addition of any reinforcement fill material or layers to create the prototype part. The disclosed method provides prototype plastic injection molded parts within a twenty-four hour time period.

Abstract: Disclosed is a method and apparatus for making a prototype injection molded part. An extruder of the type used for fused deposition modeling injects production thermoplastic material into a heated nonconductive plastic mold tool slowly at low pressure in an isothermic process. The mold tool may be built from a CAD drawing by fused deposition modeling or another rapid prototyping technique. Using the present invention, an injection molded prototype part can be made from a digital representation of the part within 24 hours by an engineer in an office environment.

Abstract: Disclosed is a method for smoothing the surface of an object built from a polymeric or wax material using a layered manufacturing rapid prototyping technique. After the object is built it is exposed to a vaporized solvent such as in a vaporizer for an exposure time sufficient to reflow the object surface. A solvent is chosen based on its ability to transiently soften the material which forms the object, and thereafter evaporate off the object. The object is removed from the solvent and allowed to dry, producing a smooth finished part.

Abstract: A modeling apparatus includes a platform and a substrate, which are adapted to be releasably locked together to provide a surface for building up models in an additive-process three-dimensional modeling machine. The substrate comprises a substantially rigid, non-dusting tray providing a modeling surface. Female connectors extending from the tray are seated in male connectors in the platform, to engage the substrate to the platform. The engaged substrate is locked to the platform, maintaining accurate positioning of the substrate while a model is built. After modeling is complete, the substrate is released from the platform, the model is removed, and the substrate may be reused.

Abstract: An apparatus which extrudes flowable material from a liquifier includes a system for loading filament supplied in a cassette. The cassette is loaded into a loading bay of the apparatus. A strand of filament from the cassette is engaged and advanced along a path to the liquifier using a drive wheel or roller pair. A conduit having an entrance in the loading bay guides the filament as it is advanced. The filament loading system of the present invention provides a convenient manner of loading and unloading filament in a three-dimensional modeling machine, and can be implemented in a manner that protects the filament from environmental moisture.

Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Abstract: The present invention is a modeling technique wherein a three-dimensional model and its support structure are built by fused deposition modeling, using a thermoplastic blended material containing a polyphenylsulfone (PPSF) polymer and a polycarbonate (PC) polymer to form the model. The PPSF/PC blend exhibits good chemical resistance, thermal stability, and resists build-up in the nozzle of a three-dimensional modeling apparatus. Removal of the support structure from a completed model is facilitated by operating on the material while it is hot.

Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: Disclosed is a modeling technique wherein a three-dimensional model and its support structure are built by fused deposition modeling, using a thermoplastic blended material containing a polyphenylsulfone (PPSF) polymer and a polycarbonate (PC) polymer to form the model. The PPSF/PC blend exhibits good chemical resistance, thermal stability, and resists build-up in the nozzle of a three-dimensional modeling apparatus. Removal of the support structure from a completed model is facilitated by operating on the material while it is hot.

Abstract: An extrusion apparatus employs a method for controlling the output flow rate of a liquifier. The apparatus includes an extrusion head which moves along a predetermined tool path at an extrusion head velocity. The extrusion head carries a liquifier. The liquifier receives a solid element of a modeling material, heats the modeling material, and outputs a flow of the modeling material at an output flow rate. A material advance mechanism is employed to supply the solid element of modeling material to the liquifier at an input rate which controls the output flow rate. In order to control the output flow rate, an extrusion head velocity profile is determined based on the tool path. The input rate of modeling material to the liquifier is then controlled to produce an output flow rate of modeling material from the liquifier that is proportional to a current extrusion head velocity corresponding to the extrusion head velocity profile.

Abstract: A filament cassette and a filament loading assembly supply modeling filament to a liquifier in a three-dimensional deposition modeling machine. Two or more cassettes containing spooled filament are inserted into the machine. A strand of filament from a first one of the cassettes is fed to the liquifier for extrusion. Without operator intervention, the filament strand from the first cassette is withdrawn from the liquifier, and a filament strand from a second one of the cassettes is fed to the liquifier. The switching of filament feed sources is triggered by an event, such as an identification that the filament from the first cassette has reached a predetermined minimum length. In this manner, a used primary filament cassette is automatically replaced with a standby filament cassette, so that the machine need not experience downtime waiting for an operator to change the cassettes.

Abstract: A process for three-dimensional modeling in which an alkali-soluble thermoplastic material is used in an additive deposition process to form a soluble support structure (28) for a three-dimensional object (26) under construction. The alkali-soluble thermoplastic material includes a base polymer of carboxylic acid and a plasticizer. Following formation, the object (26) is placed in an alkaline bath to dissolve the support structure (28). The alkali-soluble material can be used to form an alkali-soluble three-dimensional object (26).

Abstract: Disclosed are a filament cassette and a filament loading assembly for supplying filament in a three-dimensional deposition modeling machine. The filament cassette contains a rotatable spool of filament, and has an exit orifice through which a filament strand may exit the cassette. The filament loading assembly is mounted on the modeling machine and receives the filament cassette. The filament loading assembly has conduit for receiving a strand of filament from the cassette and a drive means for advancing the filament strand through the conduit. The filament cassette and loading assembly of the present invention provide a convenient manner of loading and unloading filament from the modeling machine. The filament cassette and the conduit may be made airtight so that the filament is protected from moisture in the environment.

Abstract: Filament is loaded into an extrusion apparatus, such as a three-dimensional deposition modeling machine, by inserting a cassette containing filament into the apparatus. A filament strand from the cassette is then advanced into the machine, such as by operating a thumb wheel or a follower wheel on the cassette. The filament loading method of the present invention provides a convenient manner of loading and unloading filament in a three-dimensional modeling machine, and can be implemented in a manner that protects the filament from environmental moisture.