Abstract: A method of fabricating a three dimensional model from a composite model formed by a plurality of layers. The composite model comprises at least one shell material encasing and enclosing a build material. The method comprises the steps of (1) depositing a build layer of the build material onto a preceding layer, (2) removing a selected area of the build material from the deposited build layer; (3) depositing the shell material in any removed selected area of the build material; and (4) reducing the build layer to a desired final thickness for supporting a next build layer. Then repeatedly repeating steps (1) through (4) for each build layer until the composite model is completed. Finally, the undesired extraneous material, and possibly the shell, are removed to obtain the final model.

Abstract: A method of fabricating a three dimensional model from a composite model formed by a plurality of layers. The composite model comprises at least one shell material encasing and enclosing a build material. The method comprises the steps of (1) depositing a build layer of the build material onto a preceding layer, (2) removing a selected area of the build material from the deposited build layer; (3) depositing the shell material in any removed selected area of the build material; and (4) reducing the build layer to a desired final thickness for supporting a next build layer. Then repeatedly repeating steps (1) through (4) for each build layer until the composite model is completed. Finally, the undesired extraneous material, and possibly the shell, are removed to obtain the final model.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.