Abstract: A method of fabricating footwear using sacrificial molds that are produced using additive manufacturing. A sacrificial mold for an article of footwear is manufactured from a soluble material by an additive manufacturing process. The article of footwear is then fashioned from the sacrificial mold by introducing an expandable foam into a cavity in the mold, allowing the foam to cure within the mold, and then removing the mold by exposing it to a solvent until dissolved. One or more design elements and/or rigid inserts may be introduced into areas of the mold, for example during manufacture of the mold or during fashioning of the article of footwear. For example, the manufacturing of the sacrificial mold may be temporarily paused during the manufacturing process for addition of the one or more design elements into a semi-completed mold.

Abstract: Methods and apparatus for forming a three-dimensional article in which a powdered medium is distributed in a powder bed, heated to a temperature below its melting point, and fused by means of a laser beam projected in the form of an image of a cross section of the three-dimensional article. The image of the cross-sectional layer is created by spatial light modulation of the laser beam using an LCoS display. During the fabrication process, characteristics of the image of the cross-sectional layer are controlled through monitoring of the projection of a holographic representation of the image using one or more imaging devices.

Abstract: Multiple printer housings and powder bed carts may be coordinated to perform a variety of 3D printing operations. Printer housings may call for powder bed carts directly or through a control station. A requested powder bed cart may be dispatched from a stand-by area and may navigate to the requesting printer housing autonomously using its magnetic guide sensors to follow lines of magnetic tape on the floor. At the requesting printer housing, the powder bed cart may dock, move the powdered media trays and powder bed into position by elevating on its jack screws, and printing operations may commence. As the powder bed cart becomes depleted of powdered media, the powder bed cart may decouple from the printer housing and return to the stand-by area where the trays are refilled with powdered media, and its batteries are recharged.

Abstract: Methods and apparatus for forming a three-dimensional article in which a powdered medium is distributed in a powder bed, heated to a temperature below its melting point, and fused by means of a laser beam projected in the form of an image of a cross section of the three-dimensional article. The image of the cross-sectional layer is created by spatial light modulation of the laser beam using an LCoS display. During the fabrication process, characteristics of the image of the cross-sectional layer are controlled through monitoring of the projection of a holographic representation of the image using one or more imaging devices.

Abstract: Methods and apparatus for forming a three-dimensional article in which a powdered medium is distributed in a powder bed, heated to a temperature below its melting point, and fused by means of a laser beam projected in the form of an image of a cross section of the three-dimensional article. The image of the cross-sectional layer is created by spatial light modulation of the laser beam using an LCoS display. During the fabrication process, characteristics of the image of the cross-sectional layer are controlled through monitoring of the projection of a holographic representation of the image using one or more imaging devices.

Abstract: Methods and apparatus for forming a three-dimensional article in which a powdered medium is distributed in a powder bed, heated to a temperature below its melting point, and fused by means of a laser beam projected in the form of an image of a cross section of the three-dimensional article. The image of the cross-sectional layer is created by spatial light modulation of the laser beam using an LCoS display. During the fabrication process, characteristics of the image of the cross-sectional layer are controlled through monitoring of the projection of a holographic representation of the image using one or more imaging devices.