Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: A system for building a three-dimensional object based on build data representing the three-dimensional object, the system comprising an extrusion head configured to deposit a radiation-curable material in consecutive layers, where the radiation-curable material of each of the consecutive layers is in a self-supporting state, and a radiation source configured to selectively expose a portion of at least one of the consecutive layers to radiation in accordance with the build data.

Abstract: A support material feedstock comprising a first copolymer and a polymeric impact modifier, where the first copolymer includes a first monomer unit comprising a carboxyl group and a second monomer unit comprising a phenyl group.

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 three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: The present invention is a method and apparatus for building three-dimensional models by deposition modeling techniques from moisture-sensitive thermoplastics. A feedstock of thermoplastic modeling material is dried to a low moisture content and supplied to a dispensing head of a modeling apparatus. The dry thermoplastic material is heated in a liquifier and deposited in a predetermined pattern so as to build a three-dimensional model.

Abstract: A three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: Disclosed is a method for making a prototype plastic injection molded part from a mold tool (10) built by fused deposition modeling. The mold tool (10) is built by depositing roads of a molten thermoplastic resin in layers in a predetermined pattern defined by computer file data representing the inverse of the desired prototype molded part, and is used in an injection molding machine without the addition of any reinforcement fill material or layers to create the prototype part. The disclosed method provides prototype plastic injection molded parts within a twenty-four hour time period.

Abstract: Disclosed is a method and apparatus for making a prototype injection molded part. An extruder of the type used for fused deposition modeling injects production thermoplastic material into a heated nonconductive plastic mold tool slowly at low pressure in an isothermic process. The mold tool may be built from a CAD drawing by fused deposition modeling or another rapid prototyping technique. Using the present invention, an injection molded prototype part can be made from a digital representation of the part within 24 hours by an engineer in an office environment.

Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Abstract: A process for three-dimensional modeling in which an alkali-soluble thermoplastic material is used in an additive deposition process to form a soluble support structure (28) for a three-dimensional object (26) under construction. The alkali-soluble thermoplastic material includes a base polymer of carboxylic acid and a plasticizer. Following formation, the object (26) is placed in an alkaline bath to dissolve the support structure (28). The alkali-soluble material can be used to form an alkali-soluble three-dimensional object (26).

Abstract: Disclosed are a filament cassette and a filament loading assembly for supplying filament in a three-dimensional deposition modeling machine. The filament cassette contains a rotatable spool of filament, and has an exit orifice through which a filament strand may exit the cassette. The filament loading assembly is mounted on the modeling machine and receives the filament cassette. The filament loading assembly has conduit for receiving a strand of filament from the cassette and a drive means for advancing the filament strand through the conduit. The filament cassette and loading assembly of the present invention provide a convenient manner of loading and unloading filament from the modeling machine. The filament cassette and the conduit may be made airtight so that the filament is protected from moisture in the environment.

Abstract: Disclosed are an apparatus and method for three-dimensional deposition modeling, which shield a supply of modeling filament fed through a deposition modeling machine from exposure to environmental moisture. Dry gas under pressure is supplied to a filament path leading from a material supply to a liquifier, creating an active moisture barrier along the filament path. In a preferred embodiment, an entrance of the filament path is configured to seal to an exit orifice of a cassette containing the material supply, and an exit of the filament path is vented to release exhaust gas.

Abstract: High-performance thermoplastic materials are used in building a three-dimensional model and its supports, by fused deposition modeling techniques. In a preferred embodiment, the thermoplastic resin comprising used as the modeling material is selected from the group consisting of a polycarbonate resin, a polyphenylsulfone resin, and a polycarbonate/acrylonitrile-butadiene-styrene resin. An amorphous thermoplastic resin which self-laminates, bonds weakly to the modeling material, has a heat deflection temperature similar to the heat deflection temperature of the modeling material, and has a tensile strength of between 5000 psi and 12,000 psi is used as a support material. In a preferred embodiment, the thermoplastic resin used as the support material is selected from the group consisting of a polyphenylene ether and polyolefin blend, a polyphenylsulfone and amorphous polyamide blend, and a polyphenylsulfone, polysulfone and amorphous polyamide blend.

Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Abstract: Disclosed are a method and apparatus for building three-dimensional models by deposition modeling techniques from moisture-sensitive thermoplastics. A feedstock of thermoplastic modeling material is dried to a low moisture content and supplied to a dispensing head of a modeling apparatus. The dry thermoplastic material is heated in a liquifier and deposited in a predetermined pattern so as to build a three-dimensional model.

Abstract: A three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: Disclosed are high-performance thermoplastic materials used in building a three-dimensional model and its supports, by fused deposition modeling techniques. In a preferred embodiment, the thermoplastic resin comprising the modeling material is selected from the group consisting of a polycarbonate resin, a polyphenylsulfone resin, and a polycarbonate/acrylonitrile-butadiene-styrene resin. An amorphous thermoplastic resin which self-laminates, bonds weakly to the modeling material, has a heat deflection temperature similar to the heat deflection temperature of the modeling material, and has a tensile strength of between 5000 psi and 12,000 psi comprises a support material. In a preferred embodiment, the thermoplastic resin comprising the support material is selected from the group consisting of a polyphenylene ether and polyolefin blend, a polyphenylsulfone and amorphous polyamide blend, and a polyphenylsulfone, polysulfone and amorphous polyamide blend.