Abstract: A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) operating a material deposition sub-system for dispensing droplets of solidifiable liquid compositions on demand onto selected spots of an object work surface, for using a focused heat source to maintain a heat-affected zone on the work surface, and for creating a weld pool of molten materials on this work surface by injecting selected powder particles into this heat-affected zone and (2) during the material deposition process, moving the deposition sub-system and the work surface relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the object. The material in the weld pool solidifies after the heat-affected zone moves away to build portions of a layer. These steps are repeated to deposit multiple layers for forming a three-dimensional shape.