Abstract: A method of forming a three-dimensional object comprises ejecting drops of liquefied material into a vat using an ejector; scanning the ejector in first and second mutually opposed directions to induce the drops of liquefied material from the ejector to deposit and solidify in a predetermined sequence to sequentially form layers of the three-dimensional object; supplying a viscous liquid into the vat to a level which is essentially level with the top of a most recently formed layer of the three-dimensional object; and raising the level of the viscous liquid in accordance with the formation of new layers.

Abstract: An improved stereolithography apparatus for forming three-dimensional objects using multiple chambered resin vats and a quick disconnect mounting system to permit concurrent use of multiple photopolymer build materials and easy change over of resin vats is disclosed. The apparatus permits easy change over from multiple chambered vat use to single chamber vat use and vice versa or change over between multiple chambered vats.

Abstract: High-volume mass-production and customization of complex three-dimensional polymer and polymer-derived-ceramic microstructures are manufactured in a single step directly from three-dimensional computer models. A projection based non-degenerate two-photon induced photopolymerization method overcomes the drawbacks of conventional one and two-photon fabrication methods. The structure includes dual, synchronized, high-peak power, pulsed femtosecond and picosecond lasers combined with spatial light modulation. Applications include high-resolution rapid prototyping and rapid manufacturing with an emphasis on fabrication of various Micro-Electro-Mechanical Systems (MEMS) devices, especially in the area of MEMS packaging.

Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.

Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With these methods, an ingot can be grown that is low in carbon and whose crystal growth is controlled to increase the cross-sectional area of seeded material during casting.

Abstract: The invention relates to a method and device for production of a three-dimensional article from a material, by means of layered application. According to the invention, a dropwise application is carried out, whereby drops of reaction components are ejected by a nozzle arrangement (3) and applied to a base reaction component (2), arranged on a substrate (1). The material for the three-dimensional article is formed in layers, with reaction of the base reaction component (2) with reaction components on contact, whereby the material is formed on a reaction of the base reaction component with one of the reaction components to give a material with one material property and on another reaction of the base reaction component with another of the reaction components to give a material with another material property. On production of the three-dimensional article, an article section is produced in which a gradual transition between the one material property and the other material property is generated.

Abstract: A printer system is provided for developing a three dimensional (3D) printed structure. The system includes a plurality of spaced apart sets of printing devices. A conveyor system is arranged to serially convey a print medium operatively with respect to each set so that printed voxels from each successive set can form successive layers of the 3D printed structure upon the print medium. A placement mechanism is configured to place an object upon layers of the 3D printed structure. The placement mechanism includes a translation mechanism configured to translate the object at substantially the same velocity as the conveyance of the print medium during placement of the object. A plurality of curing mechanisms is interleaved between the sets of printing devices and is configured to cure the printed voxels.

Abstract: An artificial bone forming method, comprising a) a powder layer forming step (32) for forming, into a flat powder layer (6), a powder bone material (5) having biocompatibility and hardening by hydration, b) a partial hardening step (34) for jetting an aqueous solution (7) with biocompatibility to a part of the powder layer to harden a jetted portion (6a) by hydration, and c) an artificial bone forming step (36) for repeating the steps a) and b) for lamination to form a specified artificial bone (9) of a predetermined three-dimensional structure in which the hardened portions (6a) are connected to each other.

Abstract: Shells for mammary prostheses and other devices are created by spraying a silicone dispersion onto a mandrel. Several coats of dispersion are applied with an interval for evaporation of solvent from the dispersion between application of coats. The shells created are uniform in thickness and have a desirably defect-free surface.

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 stereolithography apparatus that forms a three-dimensional model by sequentially laminating cured resin layers through repetition of a cycle of selectively applying light to liquid photocurable resin to form a cured resin layer, further applying liquid photocurable resin on the cured resin layer, and applying light to form a cured resin layer. The apparatus includes a table, a dispenser to supply the liquid photocurable resin onto the table, a recoater to apply the photocurable resin, and a controller to slow down a moving speed of the recoater based on a moving distance of the recoater during application operation of the recoater.

Abstract: A method or procedure for the construction of a laminated compound or mould made up of a number of layers of particle material on top of each other, which are hardened and joined to each other in predetermined onsite areas, which can differ from each other depending on position and expansion, so that from the predetermined hardened areas of the laminated compound at least one mould is formed. The layers are deposited individually one after another in predetermined layer thickness by the dispensing of particle material from a dispensing device during its movement above a working field and according to computer data in predetermined areas.

Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.

Abstract: A method of manufacturing a composite tower, includes at least partially filling a form with a curable resin; at least partially curing the resin in the form; raising the form partly over the at least partially cured resin; and at least partially filling the raised form with more curable resin applied against the cured resin.

Abstract: Techniques for generating tissue support structure are presented. A curved minimal surface shape is determined as a template for generating a tissue support structure. The determined curved minimal surface shape is numerically or functionally defined to create data representing the shape. The data is exported to a rapid prototyping system to generate a plurality of tissue support structures having a curved minimal surface. The tissue support structure can have a pore sub-section and a non-pore sub-section divided by a non-intersecting two-sided surface. A number of characteristics of the tissue support structure can be modulated including porosity and mechanical strength.

Abstract: A device (1) for manufacturing a three-dimensional object by a layerwise solidification of a building material at positions in the respective layers corresponding to the object is provided. The device comprises a machine frame (2, 3, 4, 5) and a building space (10) located in said machine frame, wherein in the building space (10) there are arranged: an application device (27) that applies layers of the building material onto a support device (26) and a previously solidified layer, respectively, by means of an application element (61); a dosage device (28, 29) that supplies building material from a building material accommodation region (23, 24) to the application device (27) for an application; and a heating device (31) for heating the applied layers of the building material. The building material accommodation region (23, 24) is limited by a wall that has a double-wall structure, so that a hollow space (34, 35) is formed therein.

Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.

Abstract: A method comprising building at least one three-dimensional model and a support structure using a layer-based additive technique, where the at least one three-dimensional model is at least partially encased in the support structure, and where the support structure functions as a shipping package for the at least one three-dimensional model.

Abstract: A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.

Abstract: A method for manufacturing a dental restoration, including: determining an external form and dimensions available for a completed restoration; obtaining an image of a natural tooth to be replaced with the restoration or a tooth corresponding therewith, wherein the image comprises at least the external surface visible in use of the to be replaced or corresponding tooth, with variations in the appearance therein; defining locally on and at least to visible depth below the surface of appearance-determining properties of at least one material to be applied for the restoration in accordance with the obtained image and the variations in the appearance therein; constructing the restoration, including the steps of: providing at least one material to be applied in non-cohesive form; and providing cohesion to the material in accordance with the available form and dimensions.

Abstract: A three-dimensional printer uses inkjet-type printheads to rapidly prototype, or print, a three-dimensional model. A powder feeder includes a conveyor system and a metering system to deliver powder to a build area in measured quantities. The powder feeder also includes a vacuum system for loading powder into a feed reservoir or chamber. The vacuum system can also be used to cleanup excess powder. Other powder control features include powder gutters and magnetic powder plows. During printing, a cleaning system operates to remove powder from the printheads. In the event of a printhead or jet failure, the failure can be detected and corrective measures taken automatically. After printing, the model can be depowdered and infiltrated in an enclosure.

Abstract: A device (1) for manufacturing a three-dimensional object by a layer wise solidification of a building material at positions in the respective layers corresponding to the object is provided. The device comprises a building field, in which the solidification of the material in powder form takes place; an application element (61), that applies the building material in powder form in the form of a layer; and a drive mechanism (59) that moves the application element (61) across the building field in order to apply the layer of the building material. The drive mechanism (59) is configured such that for the application of layers it moves the application element (61) between a first end position on a first side of the building field and a second end position on an opposite second side of the building field on a circular path back and forth.

Abstract: An injection process for forming a retroreflector on a matrix mold having a plurality of prisms that each define a cavity. The process includes the steps of a) injecting a first layer of plastic on the matrix mold for partially filling up each prism up to a predetermined uniform thickness so as to define a recessed portion corresponding with each cavity of the prisms; and b) injecting a second layer of plastic onto of the first layer, the second layer filling up the recessed portion defined in each cavity of the prisms so that second layer defines a flat portion on an exterior side of the second layer.

Abstract: A composite sheet material in one embodiment includes a porous core layer. The porous core layer includes a thermoplastic polymer, about 20 weight percent to about 80 weight percent of reinforcing fibers based on a total weight of the porous core layer, and an effective amount of a flame retardant agent.

Abstract: A building container (25) for a device (1) for manufacturing a three-dimensional object by a layer wise solidification of a building material in powder form at positions in the respective layers that correspond to the object is provided. A support device (26) is provided that is arranged in the building container (25) such that it is vertically movable, wherein the support device (26) has an upper side that forms a building platform (78), on which the three-dimensional object is generated layer wise. Between a circumferential outer edge of the building platform (78) and a circumferential inside wall (79) of the building container (25) a gap (80) is formed and a seal (81) is provided that is provided circumferentially at the building platform (78) and closes the gap (80). The seal is made from a ring of a flat flexible material having an outer diameter, which in a flat state is larger than the inner diameter of the inside wall (79).

Abstract: A method and a system for forming a polymeric resin mold for molding plastic items, wherein the method includes: (a) using a rapid-prototyping process to create a polymeric resin shell having a configuration in the form of the mold; (b) introducing a reinforcing material into the shell; and (c) curing the shell. The system includes a rapid-prototyping apparatus that creates a plurality of the polymeric resin shells on a platform; a reinforcing material introduction apparatus that introduces a reinforcing material into each of the shells while the shells are on the platform to form a plurality of uncured molds on the platform; and a curing apparatus that cures the shells while they are on the platform.

Abstract: A process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.

Abstract: An apparatus provides a method for transferring infiltrant to a 3D printed article comprising the steps of (i) calculating the amount of infiltrant based in part upon the particulars of the 3D printed articles; (ii) dispensing the calculated amount of infiltrant to a scale from an infiltrant dispenser through a controller; (iii) weighing the dispensed infiltrant during the dispensing; providing the controller with a signal of the weighed dispensed infiltrant; and (iv) automatically stopping the infiltrant dispenser through the controller as the weighed infiltrant reaches the calculated amount of infiltrant.

Abstract: An application device (27) for applying a layer of a building material in powder form in a device (1) for manufacturing a three-dimensional object by a layer-wise solidification of a building material at positions in the respective layers that correspond to the object is provided. An application element (61) that applies the building material in powder form in the form of a layer and a drive mechanism (59) that moves the application element (61) across a building plane (11) in order to apply the layer of the building material are provided. The drive mechanism (59) comprises an actuation piston cylinder system (69) and a brake piston cylinder system (70).

Abstract: An integrated system and method of integrating fluid dispensing technologies (e.g., direct-write (DW)) with rapid prototyping (RP) technologies (e.g., stereolithography (SL)) without part registration comprising: an SL apparatus and a fluid dispensing apparatus further comprising a translation mechanism adapted to translate the fluid dispensing apparatus along the Z-, Y- and Z-axes. The fluid dispensing apparatus comprises: a pressurized fluid container; a valve mechanism adapted to control the flow of fluid from the pressurized fluid container; and a dispensing nozzle adapted to deposit the fluid in a desired location. To aid in calibration, the integrated system includes a laser sensor and a mechanical switch. The method further comprises building a second part layer on top of the fluid deposits and optionally accommodating multi-layered circuitry by incorporating a connector trace.

Abstract: A material feed system for solid freeform fabrication. The build material is delivered in discrete or quantized amounts by a clamp 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. The clamped feed system is integrated with a waste removal system.

Abstract: The present invention achieves differential transmit diversity and related diversity reception schemes transmit symbol constellations which are extended to multiple levels. Heretofore, a group of transmission bits is divided into a first sub-group of transmission bits and a second sub-group of transmission bits. Then, the first sub-group of transmission bits is mapped (14) onto constellation points of a differential transmit diversity coding scheme from an orthogonal design for coding of the first sub-group of transmission bits. Then, after differential encoding of the constellation points (32, 34, 36, 40) a length of the transmission symbol vector is scaled (38) for coding the second sub-group of transmission bits. Therefore, the present invention overcomes restrictions implied through unit length requirements for previously known differential transmit diversity schemes from orthogonal designs.

Abstract: A method for improving color quality in an object created by a solid freeform fabrication system keeps a colorant in an ejected material near a surface of the object.

Abstract: Extra coagulant is added to the cuff portion of the former by a spray nozzle located between the coagulant and latex dipping tanks. A former is placed into a coagulant. After removal from the coagulant, additional coagulant to the cuff portion of the former by any conventional means, such as a spray nozzle. The higher concentration of coagulant at the cuff portion results in a thicker latex thickness at the cuff portion and counteracts the reduced dwell time of the cuff in the latex dipping tank as compared to the fingertip portion of the former. The thickness of the cuff portion can be controlled by altering the concentration of the coagulant applied by the spray nozzle.

Abstract: A portion of a reinforcing member has a stacked structure 102 in which plural iron plates having openings 106 are stacked. A hollow portion 107 is formed inside the stacked structure 102, so that the reinforcing member is reduced in weight. Porous bodies 103 composed of non-woven fabric of metal fibers are disposed on surfaces contacting matrixes, so that adhesion between the reinforcing member and the matrix is improved, and peeling therebetween is prevented. A cast product which is composed of light metal and has the above reinforcing member has a small thermal expansion. For example, the cast product is desirable for use for a journal portion of an engine block.

Abstract: A method for building a 3D object with an extrusion-based layered deposition system comprising feeding a modified ABS material to an extrusion head of the extrusion-based layered deposition system, melting the fed modified ABS material in the extrusion head under conditions that improve a response time of the extrusion head, and depositing the molten thermoplastic material in a layer-by-layer manner to form the 3D object.

Abstract: A method of manufacturing photonic band gap structures operable in the optical spectrum has been presented. The method comprises the steps of filling a plurality of grooves of an elastomeric mold with a UV curable first polymer, each groove in parallel with each other and partially curing the first polymer. A second polymer is coated on the first polymer. A substrate or a multi-layer polymer structure is placed on the filled mold and the resulting structure is exposed to UV light (i.e., is UV cured). The mold is peeled away from the first and second polymers such that a layer of polymer rods is formed on the substrate/multi-layer polymer structure. The process is repeated until a desired number of layers have been formed. The multi-layer structure can be used to create ceramic and metallic photonic band gaps by infiltration, electro-deposition, and/or metal coating.

Abstract: An extrusion head comprising at least one mounting structure, a first liquefier pump secured to the at least one mounting structure, a second liquefier pump disposed adjacent to the first liquefier pump, a toggle mechanism supported by the at least one mounting structure and configured to move the second liquefier pump relative to the first liquefier pump along a first axis, and a slot engagement assembly connected in part to the second liquefier pump for defining a range of motion for the second liquefier pump along the first axis.

Abstract: A method of producing an object through solid freeform fabrication includes selectively depositing a boundary structure that defines a surface of the object, and depositing a flowable build material within the boundary structure, wherein the flowable build material forms a portion of the object by flowing to the boundary structure.

Abstract: The present invention discloses a method for fabricating a carbon membrane having pore regularity. The method comprises: providing a template having a plurality of pores arranged regularly; performing a tubular carbon forming process in the regularly-arranged pores; then performing a removal process to form an annular cavity; performing a carbon forming process in the annular cavity to combine the carbon in the annular cavity with the tubular carbon to thereby form a carbon substance having a thick wall; and repeatedly performing the removal process and the carbon forming process so as to form a carbon membrane having pore regularity.

Abstract: A connector arrangement for connecting web ends (5), in particular an endless filter web, comprises two elongate elements which each have at least one elongate leg (1, 2) for fastening on one of the web ends (5), and a longitudinal flank (9) directed away from the web end (5). In a first longitudinal-section plane the longitudinal flank (9) has a first periodic contour, which engages in a corresponding contour of the other element respectively. In a second and third cross-section plane extending parallel to the first longitudinal-section plane, the elements each have second and third periodic contours (10, 11), which engage in a form-fitting manner in respectively corresponding contours (10, 11) of the other element respectively. The first to third contours form a groove (13, 13?) and a tongue (12) in at least one cross-section plane.

Abstract: A method to help control the quality of printed three-dimensional objects is provided. The method may include depositing building materials to print a three-dimensional object with an adjacent support construction such that the object and the support construction are separated by a barrier and the barrier includes vacant pixels, where no building material is deposited.

Abstract: Inventive machine allowing the simultaneous fabrication of several objects by a method of “rapid prototyping” type, by depositing a succession of layers of heat-fusible fluid. It chiefly comprises a crossbar (20) carrying two platforms (11) on each of which an object is fabricated by deposition. Two fixed work stations are arranged diametrically opposite each other so that the jet (12) of each of these fixed stations can perform a depositing operation at the same time as the other jet (12). After each deposit, the crossbar is rotated 180° to alternate the depositing operations of the two different materials. Particular application to prototyping jewellery models.

Abstract: An apparatus for forming freeform solid articles includes a head unit having a plurality of arc-shaped support arms. The support arms mount material feeders and power sources which are directed at a work table. The material feeders, power sources and movement of the head unit and work table are controlled by a computerized control system.

Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell or die used in the manufacture of a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously.

Abstract: A system for building a three-dimensional object with a layer-based additive technique, the system comprising a controller configured to receive build sequence data for the three-dimensional object, a head assembly in signal communication with the controller and configured to form a plurality of layers of the three-dimensional object based on the build sequence data, and an insert placement apparatus in signal communication with the controller and configured to place at least one insert in the plurality of formed layers based on the build sequence data.

Abstract: A sealing lip device for a breathing mask includes a receiving opening for receiving at least the nose tip region of a mask wearer, a sealing lip which is formed from an elastomeric material and which surrounds the receiving opening and which is configured to cross the bridge of the nose and which has a contact zone provided for bearing against the face of a mask wearer in use. The sealing lip is elastically and yieldingly arranged in such a way that a first sealing lip zone which in use seals the region of the bridge of the nose has a higher degree of flexibility than a second sealing lip zone which in use is adjacent to at least one of the nostrils and the upper lip of the mask wearer in the application position of the breathing mask. The sealing lip includes a folding bellows structure that suspends the sealing lip in the region of the first zone provided for sealing of the region of the bridge of the nose. The folding bellows structure includes a fold indentation having zones of differing wall thickness.

Abstract: The invention relates to an arrangement for the production of a three-dimensional product, which arrangement comprises a work bench on which the said three-dimensional product is to be constructed, a powder dispenser which is arranged to apply a thin layer of powder onto the work bench to create a powder bed, an irradiation gun for transmitting energy to the powder so that melting of the powder takes place, the arrangement comprising a casing within which the pressure is reduced in relation to the atmospheric pressure and within which the work bench and the irradiation gun are located, with the powder dispenser, or a supply pipe connected to the powder dispenser, being arranged partially outside the casing.

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.