Abstract: Modeling material formulations and formulation systems usable in additive manufacturing of a three-dimensional object, featuring, when hardened, a Shore A hardness lower than 10 and/or a Shore 00 hardness lower than 40, are provided. Additive manufacturing processes utilizing these formulations and formulation systems, and three-dimensional objects obtainable thereby, are also provided.

Abstract: A method of encoding data for additive manufacturing comprises: displaying a graphical user interface (GUI) having at least a planar segment selector control, a pattern shaping control, and a material selection control. The method also comprises displaying on the GUI a cross-section of a three-dimensional object at a position corresponding to a specific planar segment selected by the planar segment selector control. A planar pattern having nested contours is displayed over the cross-section, wherein each contour is shaped according to an input received by the pattern shaping control and is associated with at least one building material according to an input received by the material selection control. A data structure describing the planar pattern is stored in a computer storage.

Abstract: Formulation systems usable for fabricating a three-dimensional object made of a polyamide-containing material, by three-dimensional 3D inkjet printing, and methods and systems utilizing same, are provided. The formulation systems are formed of at least a first and second model formulations containing a lactam and a catalyst for inducing anionic ring opening polymerization of the lactam in the first formulation, and an activator for promoting anionic ring opening polymerization of the lactam in the second formulation, and are further characterized as: including in the first and/or second formulation a compound capable of increasing a rate of said polymerization upon exposure to said curing energy; including as an activator a lactam-blocked polyisocyanate; and/or as including in the first model formulation at least one material capable of reducing a melting point of said first model formulation. Formulation systems usable at a selected ratio are also provided.

Abstract: A waste curing device to cure waste generated by an additive manufacturing system, the waste curing device comprising: a container for receiving the waste; a movable cover positioned above the container; one or more waste nozzles mounted on the moveable cover and configured to deliver waste into the container; a static cover positioned above the container and below the movable cover; one or more curing sources mounted on the static cover and configured to provide curing radiation to cure the waste in the container; wherein the movable cover is configured to move relative to the static cover to provide an open position for the waste nozzles to deliver waste into the container, and subsequently to a closed position, to shield the waste nozzles from curing radiation.

Abstract: A system and methods for solid freeform fabrication of an object is disclosed. The system comprises a solid freeform fabrication apparatus having a plurality of dispensing heads, a building material supply apparatus configured to supply a plurality of building materials to the fabrication apparatus, and a control unit configured for controlling the fabrication apparatus and the supply apparatus based on an operation mode selected from a plurality of predetermined operation modes.

Abstract: Method and kits for handling an aqueous waste solution or dispersion obtained upon removing a water-miscible support material from a three-dimensional object during additive manufacturing of the object, and additive manufacturing processes utilizing same are provided. The methods and kits utilize a super absorbent polymeric material to convert the liquid waste solution to a solid or semi-solid composition.

Abstract: Formulations usable as support material in additive manufacturing such as 3D inkjet printing and which feature a viscosity of no more than 50 cPs at 35° C., are provided. The formulations are composed of at least one hydrophilic curable material which provides, when hardened, a material that is dissolvable or swellable in an aqueous solution; and at least one non-curable material that is capable of being swelled by said hardened material formed of said at least one curable material. Additive manufacturing processes utilizing these formulations and objects obtained thereby are also provided.

Abstract: A method of additive manufacturing of a three-dimensional object, comprises: dispensing from a first array of nozzles a modeling material formulation containing a polyimide precursor to form a layer in a configured pattern corresponding to a shape of a slice of the object; applying to the layer ultraviolet radiation and infrared radiation from two different radiation sources; and repeating the dispensing and the application of radiation to form a plurality of layers in configured patterns corresponding to shapes of other slices of the object. Optionally, an additional modeling material formulation or a support material formulation is dispensed from a second array of nozzles.

Abstract: A method of layerwise solid freeform fabrication is disclosed. The method comprises, for each of at least a few of the layers, dispensing and hardening at least a first modeling material and a second modeling material to form a core region and one or more envelope regions at least partially surrounding the core region. In some embodiments, the ratio between the elastic moduli of adjacent regions, when hardened, is from about 1 to about 20.

Abstract: Formulations usable in additive manufacturing of a three-dimensional object, which comprise a reinforcing material such as silica particles in an amount of from 10 to 30%, or from 15 to 20%, by weight, of the total weight of the formulation, and a designed combination of curable materials as described in the specification, is provided. Additive manufacturing of three-dimensional objects made of such a formulation and featuring enhanced mechanical properties, and objects obtained thereby are also provided.

Abstract: Modeling material formulations usable in additive manufacturing of a denture structure, and additive manufacturing methods employing same are provided. Kits comprising the modeling material formulation, optionally in combination with a support material formulation, are also provided.

Abstract: A system for generating slice data for additive manufacturing, comprises a graphics processing unit (GPU) that receives a digital model of an object in a three-dimensional build space defined over a plurality of slices, computes a three-dimensional signed distance field over voxels in the build space, assigns a building material to each voxel based on a respective distance field value, and generates slice data output pertaining to the building material assignments for each slice. The slice data output can be used for printing the object in layers corresponding to the slices. The distance field comprises one or more vector having a vertical component with respect to the slices.

Abstract: A method of 3D printing to achieve a desired surface quality on at least one surface of a 3D printed object comprising selecting a base surface having the desired surface quality; and printing the 3D printed object on the base surface, so that the desired surface quality is imparted to one surface of the 3D printed object during printing. The surface quality may be glassiness, roughness, smoothness and texture in general. Objects may thus be manufactured in which electronic components are integrated in or under a glass-like surface.

Abstract: A system and methods for solid freeform fabrication of an object is disclosed. The system comprises a solid freeform fabrication apparatus having a plurality of dispensing heads, a building material supply apparatus configured to supply a plurality of building materials to the fabrication apparatus, and a control unit configured for controlling the fabrication apparatus and the supply apparatus based on an operation mode selected from a plurality of predetermined operation modes.

Abstract: A system for three-dimensional printing comprises: a three-dimensional printing apparatus for printing an object using a building material supplied from a container, and a computer. The computer is configured to receive working hours of personnel operating the apparatus, to calculate, based on three-dimensional printing data describing the object, a supply period during which the container is expected to be emptied, and to transmit to the apparatus a signal to initiate the printing at a delayed time selected to ensure that an end time of the supply period is within the working hours.

Abstract: A curable formulation that provides, when hardened, an elastomeric material which is usable in additive manufacturing of a three-dimensional object is provided. The formulation is based on curable mono-functional and multi-functional elastomeric materials, in combination with a curable, multi-functional, non-elastomeric material and a curable material that comprises at least two hydrogen bond forming groups.

Abstract: Methods, systems and formulations of building a three-dimensional object with a glossy surface, the method may include: selectively depositing a first material in a plurality of layers to form a body region of the three-dimensional object, wherein said first material comprises a multifunctional acrylic monomer; selectively depositing a second material in a plurality of layers to form a support region, wherein said second material comprises a monofunctional hydrophilic acrylic monomer and does not comprise a multifunctional acrylic monomer; curing each of the deposited layers, wherein in at least one of the deposited layers the first material and the second material mix to form an intermediate region at their mutual interface; dissolving the support region in an aqueous solution; and drying the body region and the intermediate region, whereby the dried intermediate region provides a glossy surface on the body region of said three-dimensional object.

Abstract: A method of additive manufacturing of a three-dimensional object, comprises: dispensing from a first array of nozzles a modeling material formulation containing a polyimide precursor to form a layer in a configured pattern corresponding to a shape of a slice of the object; applying to the layer ultraviolet radiation and infrared radiation from two different radiation sources; and repeating the dispensing and the application of radiation to form a plurality of layers in configured patterns corresponding to shapes of other slices of the object. Optionally, an additional modeling material formulation or a support material formulation is dispensed from a second array of nozzles.

Abstract: A support material formulation for use in additive manufacturing of a three-dimensional object, which, when hardened, is soluble upon immersion in water, is provided. The formulation includes a hydrophilic curable mono-functional material; a polyol (e.g., a branched polyol) having a molecular weight lower than 1,000, or lower than 800 grams/mol; and a polyester material having a molecular weight higher than 400, or higher than 500, grams/mol. Additive manufacturing using the disclosed formulation and objects made thereby are also provided.