Abstract: An inert gas dispenser for mounting to a process equipment functional window is provided to dispense an inert gas in a laminar flow at an effective velocity across the exposed surface to form a curtain of inert gas across the exposed surface to prevent a build-up of chemical by-product from the powder material during laser sintering. The gas flow rate is characteristic of a flow geometry having a Reynolds number below the turbulent range. The diffuser is used in a laser sintering system.

Abstract: A thermal management system is provided to control the preheating and cool down of a removable build chamber in a laser sintering system. A thermal management station controls preheating of a removable build chamber to heat the chamber to a temperature at or near the operating temperature of the laser sintering system. After insertion into the laser sintering system and completion of a build the thermal management station controls the cool down of the part cake within the removable build chamber after the chamber has been removed from the laser sintering system.

Abstract: The invention is a method for controllably cooling at least a portion of a part-cake from a laser sintering system to minimize cool down time, maximize throughput, and minimize thermal gradients within the part-cake. The method generally comprises forming one or more thermal transfer channels within the part-cake. The thermal transfer channels can include ducts and cooling fins in the part-cake surrounding the formed part. The method can further comprise removing unfused powder from the ducts and introducing cooling media into the ducts. The invention also includes a part-cake having thermal transfer channels formed therein and a laser sintering apparatus comprising a part-cake containing cylinder having permanent fittings therein for receiving terminal portions of thermal transfer channels formed in the part-cake.

Abstract: A by-product waste material removal system for solid deposition modeling. As excess build and support material is removed during the build as a by-product waste the removal system accumulates, measures, and releases the by-product waste material into a waste receptacle for disposal. The by-product waste material removal system requires no mechanical vacuum systems and allows operator intervention to remove and replace waste receptacles without interrupting an ongoing build.

Abstract: A material feed system for solid freeform fabrication. The build material is delivered in discrete or quantized amounts by the feed system in a non-flowable state to the dispensing device and the material is then changed to a flowable state prior to being dispensed. The feed system can be used to build three-dimensional objects in color, if desired. In one embodiment individual cartridges with build material are loaded into a magazine on the feed system which is integrated with a waste removal system. As the build material is expelled from the cartridges, waste material is deposited into the cartridge. Once all the build material has been expelled, the waste material is hermetically sealed in the spent cartridge which is then ejected from the system. The hermetically sealed cartridges protect operators from contact with the reactive waste material making the system safe for the office environment.

Abstract: A material feed system for solid freeform fabrication. The build material is delivered in discrete or quantized amounts by the feed system in a non-flowable state to the dispensing device and the material is then changed to a flowable state prior to being dispensed. The feed system can be used to build three-dimensional objects in color, if desired. In one embodiment individual cartridges with build material are loaded into a magazine on the feed system which is integrated with a waste removal system. As the build material is expelled from the cartridges, waste material is deposited into the cartridge. Once all the build material has been expelled, the waste material is hermetically sealed in the spent cartridge which is then ejected from the system. The hermetically sealed cartridges protect operators from contact with the reactive waste material making the system safe for the office environment.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) apparatus includes a secondary frame located within a primary frame of the system. The secondary frame defines an enclosure for housing a number of peripheral heat-producing components and peripheral vibration-producing components. The heat generated by these peripheral heat-producing components is substantially isolated in the enclosure and is removed from the primary frame so as not to cause an undesired impact on other components within the main frame. The secondary frame preferably sits directly on the floor or other surface without touching the primary frame, thus substantially avoiding transmittance of vibration from components in the enclosure to the primary frame of the system.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects with enhanced control of the temperature of the build environment. A modulated control signal is supplied to a heating element based on a difference between a desired build temperature and a detected temperature. The modulated signal result in the heater supplying, on average, more energy to the build chamber when the temperature difference is large and supplying, on average, less energy to the build chamber when the difference is small. The detection of the build chamber temperature may occur at one or more locations. If multiple locations are used, the detected temperatures may be averaged, or otherwise combined, to derive a single difference value that will be used to control the heater.