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: 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: A fused deposition process is used to form three-dimensional solid objects from a mixture including a particulate composition dispersed in a binder. The article is formed by depositing the mixture in repeated layers of predefined thickness, with each layer solidifying before the next adjacent layer is dispensed. Following formation and a binder removal step, the article may be at least partially densified to achieve preselected properties. The process permits three-dimensional articles to be formed relatively quickly and inexpensively, without the need for molds or other tooling.

Abstract: A catheter is disclosed having a proximal shaft formed from an inner liner formed from a copolymer of polyvinylidene fluoride and hexafluoropropylene, an outer jacket formed from a blend of nylon and polyether block amide or polyether block amide alone, and a soft flexible tip affixed to the distal end of the proximal shaft formed from polyether block amide. A stem may be located between the proximal shaft and the soft flexible tip. The stem has an outer jacket formed from a proximal stem transition sleeve with a tapered distal end and a distal stem sleeve with a complementary tapered proximal end connected to the tapered distal end of the proximal stem transition sleeve. The stem transition sleeve and the stem sleeve are both formed from polyether block amide alone or a blend of polyether block amide and nylon. The outer jacket may be the same hardness as or harder than the stem transition sleeve which in turn is harder than the stem sleeve and the soft flexible tip.

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.