Abstract: A mold material formulation usable as mold material in a cast-mold process, in combination with a cast material formulation, is provided. The mold material formulation comprises a paraffin wax, a vegetable-based (natural) wax and a Fisher-Tropsh wax, as described and defined in the specification. Methods employing the formulation and objects and products obtained therefrom are also provided.

Abstract: A method of printing layers using a plurality of printheads, to achieve a printed surface of even thickness by compensating for printing density differences between the printheads, comprising obtaining for each of said print heads a relative printing strength, calculating a compensation value for each print head; and carrying out printing of a layer, wherein each print head is operated according to said compensation value.

Abstract: A method of forming a base for additive manufacture in order to print an object or part object on the wax base involves forming the wax base on a printing tray. The base is constructed by providing a layer of wax on a surface of said printing tray. The wax is heated to above a melting point thereof so that the wax in contact with the tray is molten, and then the wax is slowly cooled while continually pressing on the wax. The slow cooling ensures a bond between the wax and the printing tray which may be enhanced if the tray surface is roughened.

Abstract: An additive manufacturing machine and associated method for making a part layerwise by firstly using additive manufacture to make a mold to define a space for the layer, and secondly filling the space with a paste to make a layer of the part. The machine comprises a first mold forming station with inkjet nozzles to form the mold using standard 3D printing, and a second paste dispensing station distanced from the first station, with a dispensing die slot for dispensing paste into the space to form a layer. The machine operates on multiple parts simultaneously, each being conveyed along a path through the stations.

Abstract: A layering device for preparation of layers being formed in additive manufacture, each layer formed by printing a mold wall to define a mold space and filling the mold space with a paste to form the layer. The layering device comprises a roller to press the mold wall from above to form a mold layer surface in a plane, a paste applicator and a blade to spread the paste to fill the mold space. The blade is aligned into the plane to smooth the paste flush with the mold layer surface.

Abstract: A sinterable paste formulation usable as cast material in a cast-mold process, in combination with a mold material formulation, is provided. The sinterable paste formulation comprises a power of a sinterable material, in an amount of at least 85% by weight of the total weight of the formulation, a binder as described in the specification, and an aqueous solution which comprises water and a water-miscible organic solvent featuring an evaporation rate in a range of from 0.3 to 0.8 on an n-butyl acetate scale. Methods employing the formulation and objects and products obtained therefrom are also provided.

Abstract: A method for making a product or a part for a product wherein the product or part is made in a process using additive manufacture and requires sintering, the method comprising producing a support component with a shape complementary to the product or part, in an associated process, also using additive manufacture; and supporting the product or part during sintering by fitting the product or part into the complementary shape prior to placing in the furnace for sintering.

Abstract: Apparatus and method for hardening a paste within walls of a mold, comprises a sealing hood that opens to a first position allowing paste to be applied within the mold and then closes to provide an airtight seal around the mold and the paste applied within the mold. Then a vacuum source evacuates air from the sealing hood in its closed position to apply a vacuum to the paste. The vacuum causes liquids to evaporate from the paste, and thus hardens the paste.

Abstract: Method and apparatus for manufacturing a molded layered product comprises: printing a first mold to define one layer of the product; filling the first mold with a cast material, thereby forming a first layer; printing a second mold on top of the first layer to define a second layer; and filling the second mold, over the first layer, with a cast material. The cast material may be a paste. The alternative mold printing and casting are continued until a molded layered product or part product is formed.