Abstract: Solid freeform fabrication systems, powder supply bins for solid freeform fabrication systems, and methods of solid freeform fabrication are disclosed. One exemplary solid freeform fabrication system includes a removable powder supply bin, a build bin, a roller, and a print head disposed above the build bin that deposits a binder onto the powder in the build bin in a preselected pattern.

Abstract: A material for use in fabricating three-dimensional objects includes a mixture of thermoplastic particles and a water-soluble polymer matrix formed as a film that is fusible into a non-water soluble state when exposed to heating. The film further includes a surfactant system bound to the thermoplastic particles, the surfactant system providing an inversion property such that the thermoplastic particles are hydrophilic but, upon a fusing of the film, become hydrophobic as the surfactant become incorporated into the bulk.

Abstract: A method for creating a three-dimensional solid freeform fabrication object with phase-change material includes depositing a bulk amount of phase-change material in a defined region, selectively ink-jetting an ultraviolet initiator onto a predetermined area of the phase-change material, wherein the ultraviolet initiator defines a cross-sectional area of the three-dimensional object, and exposing the ultraviolet initiator to an ultraviolet light to cause cross-linking of the defined region.

Abstract: A powder system for use in solid freeform fabrication. The powder system includes at least one polymer having reactive properties and fusible properties. The at least one polymer is reactive with a liquid binder and is fusible at a temperature above the melting point or glass transition temperature of the at least one polymer. The at least one polymer may be a single co-polymer having at least one reactive portion and at least one fusible portion or may be a mixture of polymers including at least one reactive polymer and at least one fusible polymer. A method of forming an object by solid freeform fabrication is also disclosed.

Abstract: A method for creating a three-dimensional solid freeform fabrication object with non-reactive powder includes spreading a non-reactive powder on a substrate, selectively dispensing a reactive resin onto the non-reactive powder forming a mixture of reactive resin and non-reactive powder, wherein the selective dispensing the reactive resin defines the three-dimensional object, and curing the reactive resin thereby encapsulating the non-reactive powder.

Abstract: The present invention is drawn toward systems and methods for free-form fabrication of solid three-dimensional objects. In one embodiment, a method can comprise a) ink-jetting a first ink-jettable composition containing a reactive build material and a second ink-jettable composition containing a curing agent separately onto a substrate such that contact between the reactive build material and the curing agent occurs, thereby resulting in a reaction that forms a solidifying composition, and b) repeating the ink-jetting step such that multiple layers of solidifying composition are accrued, wherein said multiple layers are successively bound to one another to form the solid three-dimensional object.