Abstract: The present invention is a method (10) for manufacturing a three-dimensional object. The method (10) includes receiving (14) digital information of the three-dimensional object over a communication line and building (30) the three-dimensional object based at least in part on the received digital information, where at least part of the three-dimensional object is built by rapid manufacturing, and where the three-dimensional object comprises an exterior surface. The method also includes vapor smoothing (32) at least a portion of the exterior surface of the three-dimensional object.

Abstract: A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.

Abstract: A compounding system for forming a customized consumable material, comprising a plurality of drive mechanisms configured to feed stock materials at independent rates, and an extrusion component configured to receive the fed stock materials, and further configured to at least partially melt and blend the received stock materials to provide the consumable material in an extrudable state. Upon solidifying, the consumable material comprises customized characteristics based on characteristics of the stock materials.

Abstract: A system and method is provided for vapor smoothing a rapid manufactured three-dimensional object. A cabinet housing has a sealable interior. A heated vapor chamber in the interior of the cabinet housing contains solvent that is vaporizable to fill the vapor chamber with vapor for smoothing the object when the object is placed in the vapor chamber. A drying chamber is also provided in the interior of the cabinet housing that is separate from the vapor chamber for drying the object when the object is moved from the vapor chamber to the drying chamber.

Abstract: A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.

Abstract: The present invention is a method (10) for manufacturing a three-dimensional object. The method (10) includes receiving (14) digital information of the three-dimensional object over a communication line and building (30) the three-dimensional object based at least in part on the received digital information, where at least part of the three-dimensional object is built by rapid manufacturing, and where the three-dimensional object comprises an exterior surface. The method also includes vapor smoothing (32) at least a portion of the exterior surface of the three-dimensional object.

Abstract: The present invention is a method for forming an object, the method comprising jetting a first material to form a plurality of layers that define a support structure increment, and extruding a second material to form a layer of the object. The layer of the object substantially conforms to an interior surface of the support structure increment.

Abstract: A method for forming a surface-treated, three-dimensional object, comprising: solvent smoothing an exterior surface of a rapid-manufactured, three-dimensional object, and media blasting at least a portion of the solvent-smoothed exterior surface.

Abstract: The present invention is a method for forming an object, the method comprising jetting a first material to form a plurality of layers that define a support structure increment, and extruding a second material to form a layer of the object. The layer of the object substantially conforms to an interior surface of the support structure increment.

Abstract: An apparatus and method for controlling the extrusion of thermoplastic through one or more discharge orifices is described. An apparatus comprises one or more thermally conductive flow tubes defining flow channels in a heated thermally conductive body and terminating in discharge orifices. Each flow channel may be independently valved on and off, by selectively supplying a flow of coolant. An array of flow channels can be independently opened and closed in a predetermined pattern, so as to vary the extrudate configuration of thermoplastic emerging from the discharge orifices. By extruding thermoplastic layer-by-layer onto a base in this manner, a three-dimensional object may be formed.

Abstract: An electrically operated apparatus and method for altering the flow resistance experienced by a thermoplastic passing through a flow channel using one or more thermal valves having a short response time is described. The extrudate configuration of thermoplastic emerging from one or more extrusion orifices is alterable by selectively opening one or more of thermal valves that supply thermoplastic to the one or more extrusion orifices. Each thermal valve is cooled by a heat sink and has an associated heater responsive to control signals. Each heater is independently activated in synchronization with movement of the apparatus in a predetermined spatial pattern with respect to a base. By extruding thermoplastic onto a base layer-by-layer in this manner, a three-dimensional object may be formed.

Abstract: A volumetric feed control apparatus for a build material element such as a filament used in a three-dimensional modeling machine having an application tip includes a pair of feed rollers feeding the filament to the application tip, and a sensor or sensor system feeding information to a central processing unit that continuously computes the effective cross section of the filament using the signals received from the sensor or sensor system. The central processing unit controls the speed of a DC servo or stepper motor which in turn rotates the feed rollers to advance the filament toward the application tip of the modeling machine. The central processing unit adjusts the speed of the feed rollers to supply a constant flow rate of material to the application tip. Alternatively, the sensor system can be incorporated into the feed rollers, eliminating the need for further space constraints.

Abstract: Processes and apparatus are disclosed for producing three-dimensional objects having overhanging portions freely suspended in space without any material of the object in direct, supporting engagement therewith in the final geometry of the object. A support structure is formed by depositing material which will be under the ultimately suspended portions of the object to be formed, during a process in which material is built up in layers to form the object as well as the underlying support structure. A readily removable support structure is formed along an interface with the underside of the suspended portion of the object structure. A weak, removable or breakable joint is formed along that interface by the use of an interface material which forms a weak or dissolvable bond with the material of the object. The release material may be deposited as a separation layer, or as a thin coating.