Abstract: Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including at least one component of a binder system and dispersed particles can be exposed to an activation light source. The activation light source can cure the at least one component of the binder system to form a green object, which can include the at least one component of the binder system and the particles. A dense object can be formed from the green object by removing the at least one component of the binder system in an extraction process and thermally processing particles to coalesce into the dense object.

Abstract: Devices, systems, and methods are directed to the use of nanoparticles for improving fabrication of three-dimensional objects formed through layer-by-layer delivery of an ink onto a powder of metal particles in a powder bed. More specifically, the ink may include metal oxide nanoparticles and reducing agent nanoparticles in a stable form, providing a shelf-life suitable for transportation and storage of the ink in large-scale commercial operations. The ink may be delivered onto the powder of the metal particles in the powder bed, where the metal oxide nanoparticles and the reducing agent nanoparticles may interact with one another to form metal nanoparticles. In turn, the metal nanoparticles may interact with the metal particles in the powder bed to improve strength of the three-dimensional objects being fabricated and, also or instead, to reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects.

Abstract: Devices, systems, and methods are directed to the use of nanoparticles for improving fabrication of three-dimensional objects formed through layer-by-layer delivery of an ink onto a powder of metal particles in a powder bed. More specifically, the ink may include metal nanoparticles suspended in a non-oxidizing aqueous solution to facilitate maintaining the metal nanoparticles in a stable form, providing a shelf-life suitable for transportation and storage of the ink in large-scale commercial operations. The ink may be delivered onto the powder of the metal particles in the powder bed, where the nanoparticles may interact with the metal particles to improve strength of the three-dimensional objects being fabricated. Also, or instead, the nanoparticles may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects (e.g., slumping and shrinking and/or inadequate densification of the final part).

Abstract: Devices, systems, and methods are directed to the use of nanoparticles for improving fabrication of three-dimensional objects formed through layer-by-layer delivery of an ink onto a powder of metal particles in a powder bed. More specifically, the ink may include nanoparticles of an inorganic material (e.g., a metal) that undergoes at least one phase change as the three-dimensional objects are heated. This phase change may facilitate achieving more uniform distribution of the inorganic material relative to the metal particles in the three-dimensional objects which, in turn, may improve strength of the three-dimensional objects being fabricated. Further, or instead, improved distribution of the inorganic material may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects.

Abstract: Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including a first binder, a second binder, and dispersed particles can be exposed an activation light source to cure at least one of the binders in a layer-by-layer process to form a green object including the first binder, the second binder, and the particles. A dense object, such as a metal object, a ceramic object, or a combination thereof, can be formed from the green object by thermally processing the particles and removing the first binder through a primary debinding process, removing the second binder through a secondary debinding process different from the primary debinding process.

Abstract: Systems, methods, and components are disclosed for controlling layer separation in stereolithographic fabrication of three-dimensional objects. Each layer of the three-dimensional object can be cured and separated in discrete portions to facilitate controlling forces in the layers of a three-dimensional object. For example, controlling curing and separation of layers of a three-dimensional object according to the systems, methods, and components disclosed can facilitate accurately forming the three-dimensional object from cured particle-loaded resins. More specifically, particle loading can decrease the shear strength of the cured resin and, thus, controlling the forces exerted on a given layer of a cured particle-loaded resin can be particularly useful for reducing the likelihood of deformation in a three-dimensional object including the particles. In turn, the accurately formed three-dimensional object including the particles can be densified to form a dimensionally accurate finished part.

Abstract: An apparatus for performing a contact mechanics test on a substrate includes a stylus, a core configured to engage the stylus against the substrate, a stylus engagement mechanism configured to induce a contact load or a penetration depth to the stylus, a core engagement mechanism configured to maintain contact of the core and to move the core along the substrate surface, a frame configured to be fixed with respect to the apparatus or to be moved together with the core engagement mechanism as an assembly, a frame engagement mechanism configured to engage the frame with the substrate surface; and a substrate monitoring device configured to measure characteristics of substrate contact response and/or collect material machined from the substrate. Methods of performing a contact mechanics test are also provided.

Abstract: An apparatus for performing a contact mechanics test on a substrate includes a stylus, a core configured to engage the stylus against the substrate, a stylus engagement mechanism configured to induce a contact load or a penetration depth to the stylus, a core engagement mechanism configured to maintain contact of the core and to move the core along the substrate surface, a frame configured to be fixed with respect to the apparatus or to be moved together with the core engagement mechanism as an assembly, a frame engagement mechanism configured to engage the frame with the substrate surface; and a substrate monitoring device configured to measure characteristics of substrate contact response and/or collect material machined from the substrate. Methods of performing a contact mechanics test are also provided.

Abstract: An apparatus for performing a contact mechanics test on a substrate includes a stylus, a core configured to engage the stylus against the substrate, a stylus engagement mechanism configured to induce a contact load or a penetration depth to the stylus, a core engagement mechanism configured to maintain contact of the core and to move the core along the substrate surface, a frame configured to be fixed with respect to the apparatus or to be moved together with the core engagement mechanism as an assembly, a frame engagement mechanism configured to engage the frame with the substrate surface; and a substrate monitoring device configured to measure characteristics of substrate contact response and/or collect material machined from the substrate. Methods of performing a contact mechanics test are also provided.

Abstract: An apparatus for performing a contact mechanics test on a substrate includes a stylus, a core configured to engage the stylus against the substrate, a stylus engagement mechanism configured to induce a contact load or a penetration depth to the stylus, a core engagement mechanism configured to maintain contact of the core and to move the core along the substrate surface, a frame configured to be fixed with respect to the apparatus or to be moved together with the core engagement mechanism as an assembly, a frame engagement mechanism configured to engage the frame with the substrate surface; and a substrate monitoring device configured to measure characteristics of substrate contact response and/or collect material machined from the substrate. Methods of performing a contact mechanics test are also provided.

Abstract: Mixture for use in a three-dimensional printer to make molds suitable for producing ferrous coatings. The mixture includes cement, sand and accelerator. Grain sizes of the cement, sand and accelerator are selected to assure that the three-dimensional printer generates coherent layers.

Abstract: Mixture for use in a three-dimensional printer to make molds suitable for producing ferrous coatings. The mixture includes cement, sand and accelerator. Grain sizes of the cement, sand and accelerator are selected to assure that the three-dimensional printer generates coherent layers.

Abstract: A three-dimensional printing materials system and method can produce both appearance models and small numbers of functional parts in an office environment. The method can include building cross-sectional portions of a three-dimensional article, and assembling the individual cross-sectional areas in a layer-wise fashion to form a final article. The individual cross-sectional areas can be built by using an ink-jet printhead to deliver an aqueous solvent or binder to an adhesive particulate mixture, causing the particles of the mixture to adhere together, and to previous cross-sectional areas. The binder can include at least one of nonaqueous organic monomeric compound, anionically ionizable polymer, cationic polymer, polymer, waterborne colloid, or inorganic solute.