Abstract: An apparatus and method of manufacture for an integral three-dimensional object of unlimited complexity formed from individually contoured laminations (layers) produced from thin sheet materials that are stabilized on a removable carrier and formed both along and across the sheet material prior to stacking the contoured laminations in precise registration to one another. The waste material surrounding the laminations and the carrier is separated from the desired object. An optional method includes refilling the space surrounding the layers with another material and leveling the upper surface of the laminations. The process of forming the contoured laminations, separating the waste material, bonding, and stacking is continued until the construction of the desired three-dimensional object is complete.

Abstract: The present invention generally relates to manufacturing apparatus, method of manufacture, and products manufactured thereby and more particularly to an integral three-dimensional object (6, 15) formed from individually contoured laminations (4, 62) of the same or gradually varying shape, successive laminae of that object being produced out of thin sheet or powder based materials (1, 60) through the cutting, fusing or physicochemical property changing action generated by a computer directed beam (7) of concentrated energy or matter, successive substantially planar laminations (4, 62) of that object (6, 15) being automatically stacked together for step-wise laminar buildup of the desired object (6, 15).

Abstract: A laminated object manufacturing (LOM) system for forming a plurality of laminations into a stack to create a three-dimensional object. The system includes an X-Y plotter device positioned above a work table, the work table being vertically movable. The X-Y plotter device includes a forming tool for forming a layer from a sheet of material positioned on the work table. The layers are bonded to each other with heat sensitive adhesives provided on one side thereof. A bonding tool or fuser is mounted to translate across the work table and apply a lamination force and heat to each of the layers. The X-Y plotter device and bonding tool are mounted to translate along rails mounted on a common reference frame. The reference frame includes two rigid beams positioned on a base frame. A sensor is provided between the bonding tool and the reference frame to sense the force applied by the bonding tool to the laminations and adjust the height of the work table in response thereto.

Abstract: The present invention generally relates to manufacturing apparatus for forming an integral three-dimensional object from individually contoured laminations of the same or gradually varying shape, successive laminae of that object being produced out of thin sheet or powder based materials through the cutting, fusing or physicochemical property changing action generated by a computer directed beam of concentrated energy or matter, successive substantially planar laminations of that object being automatically stacked together for step-wise laminar buildup of the desired three-dimensional object.

Abstract: The present invention generally relates to manufacturing apparatus, method of manufacture, and products manufactured thereby and more particularly to an integral three-dimensional object (6, 15) formed from individually contoured laminations (4, 62) of the same or gradually varying shape, successive laminae of that object being produced out of thin sheet or powder based materials (1, 60) through the cutting, fusing or physiochemical property changing action generated by a computer directed beam (7) of concentrated energy or matter, successive substantially planar laminations (4, 62) of that object (6, 15) being automatically stacked together for step-wise laminar buildup of the desired object (6, 15).

Abstract: An apparatus and method for forming an integral three-dimensional object from laminations of the same or gradually varying shape. The apparatus includes a supply station, a work station for forming a material into a plurality of laminations for the three-dimensional object, a control station for directing the operation of the work station, an assembling station for stacking the laminations in sequence into the three-dimensional object, and bonding the laminations to complete the formation of the three-dimensional object.