Abstract: A system and method for toolpath creation is provided. The method includes exporting CAD defined 3-D geometry to a slicing module; slicing the 3-D geometry creating a set of 2-D patterns representing the 3-D geometry; generating vector code from the set of 2-D patterns; and translating the vector code to machine code.

Abstract: Systems and methods of reproducing images onto surfaces are disclosed. In one embodiment, the system includes an image file that digitally produces a planar surface normal to a surface of a master model. The planar surfaces are referenced to a coordinate system of the master model through a series of points. A tracker surfacing system, comprising a tracking instrument, generates and emits a signal as the tracking instrument crosses the planar surface. An output device is actuated by the tracking device as it crosses the planar surface, reproducing the series of points as an image onto a surface, including a flat, curved or compound surface. Both the spatial position and orientation of the output device are detected and adjustments are made so that the image is precisely applied to intended locations on the surface being imaged.

Abstract: A part having an integrated, discrete component is produced by direct digital manufacturing and rapid, solid free-form fabrication techniques. A CAD file representing the part is modified to include an opening in the body of the part in which the component is to be inserted. The fabrication is performed by additive layering of a thermoplastic material, preferably using fused deposition modeling or stereolithography. The layering process is interrupted to allow the component to be inserted in the partially formed part, following which additional layers are added which secure the component in the part in place and complete the physical structure of the part.

Abstract: In accordance with the present invention a method for the direct manufacture of aerospace duct elements is provided comprising executing a single build run on a build chamber using direct fabrication technology to generate at least one duct section. The at least one duct section is generated by forming a plurality of partial cylinder duct segments orientated within the build chamber in a nested arrangement during the single build run, and assembling at least two of the partial cylinder duct segments to form the duct section. During the single build run a plurality of stiffening protrusions are formed on each of the partial cylinder duct segments during to improve duct rigidity.

Abstract: In accordance with the present invention a method for the direct manufacture of aerospace duct elements is provided comprising executing a single build run on a build chamber using direct fabrication technology to generate at least one duct section. The at least one duct section is generated by forming a plurality of partial cylinder duct segments orientated within the build chamber in a nested arrangement during the single build run, and assembling at least two of the partial cylinder duct segments to form the duct section. The duct section has a duct cross-sectional profile larger than a build chamber profile.

Abstract: A monitoring device and method is disclosed for monitoring the saturation level of resin in solvent baths, such as those used to remove resin from objects form by stereolithography. The monitoring device operates by monitoring an electrical characteristic, such as impedance, of the solvent bath as the resin-to-solvent ratio of the bath increases during use. Signals are provided by the monitoring device to the operator of the liquid storage device containing the solvent bath in a manner allowing the operator to determine when the solvent bath has reached the end of its useful life.