Abstract: Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising: a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices; a shuttle to which the printing heads are mounted; a support surface; and a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers; wherein each printing head is dismountable from the shuttle and replaceable independently of the other printing heads.

Abstract: A method for producing an object formed through solid freeform fabrication includes dispensing a binder on successive layers of build material with a single first dispensing member; and coloring the successive layers with at least one second dispensing member, where the second dispensing member over-dispenses the first dispensing member. Another method for producing an object through solid freeform fabrication includes dispensing a first binder on successive layers of build material with a single first dispensing member; and dispensing a second binder on the successive layers of build material with at least one second dispensing member, where the second dispensing member over-dispenses the first dispensing member.

Abstract: A method of manufacturing a multi-layer panel having a curved reflective and/or transmitting facing layer that includes the steps of increasing and/or decreasing pressure on a side of a thin membrane to form a pressure differential across the thin membrane that causes the thin membrane to deform to a required shape; applying a first layer of material to an outer surface of the thin membrane while the thin membrane is maintained in the required shape by the increase and/or decrease in pressure, and allowing the first layer of material to cure for a pre-determined time.

Abstract: A method for manufacturing a three-dimensional object by successively solidifying layers of a building material at positions in the respective layer corresponding to the cross-section of the object is provided, wherein at least a partial region of a layer is solidified such that a pattern is generated, which pattern contains a plurality of substantially parallel solidification lines (V, S), and at least a partial region of a subsequent layer is exposed such that a pattern is generated, which pattern contains a plurality of substantially parallel solidification lines (V, S) that are rotated with respect to the solidification lines of the pattern of the previous layer by an angle (?) that differs from 180°, 90° and 45°.

Abstract: A digital manufacturing system for producing first and second objects comprises a platen, a gantry, a pantograph extrusion head system and first and second sets of extruders. The platen defines a workspace upon which the objects are produced. The gantry defines a headspace displaced from the workspace. The extrusion head system is mounted to the gantry for movement in the headspace. The sets of extruders are connected to the extrusion head system and are configured to deposit extrusion material on the workspace to build the objects. Each set of extruders comprises a first extruder mounted to the extrusion head system; a second extruder mounted to the extrusion head system so as to be actuatable from a first to a second position; and a flexible linkage connecting the extruders. The flexible linkages position the second extruders in approximately equal known spatial relationships to the first extruders in the second positions.

Abstract: The present invention is directed to micro- and nano-scale imprinting methods and the use of such methods to fabricate supported and/or free-standing 3-D micro- and/or nano-structures of polymeric, ceramic, and/or metallic materials. In some embodiments, a duo-mold approach is employed in the fabrication of these structures. In such methods, surface treatments are employed to impart differential surface energies to different molds and/or different parts of the mold(s). Such surface treatments permit the formation of three-dimensional (3-D) structures through imprinting and the transfer of such structures to a substrate. In some or other embodiments, such surface treatments and variation in glass transition temperature of the polymers used can facilitate separation of the 3-D structures from the molds to form free-standing micro- and/or nano-structures individually and/or in a film.

Abstract: 1. A powder bed additive layer manufacturing system including a linear traversing re-coater and a build plate characterised in that the build plate is mounted for rotation, relative to the re-coater or movement about an axis.

Abstract: A three-dimensional object forming apparatus forms a three-dimensional object by binding powder particles with a curable liquid. The apparatus includes a powder layer forming unit that spreads a powder to a uniform thickness to form a powder layer. A curable liquid ejection head ejects the curable liquid to the powder layer through an ejection nozzle. A sectional data producing device produces sectional data at each of a plurality of cross sections of a desired three-dimensional object according to shape data of the desired three-dimensional object. A cross-sectional member forming section is also included by which cross-sectional members are formed by ejecting the curable liquid to the powder layer from the curable liquid ejection head according to the sectional data and thus binding the powder layer. The cross-sectional member forming section includes a permeation rate controller controlling the permeation rate of the curable liquid to the powder layer.

Abstract: A method of producing a three-dimensional structure contains the steps of: arranging a substrate close to a tip of a needle-shaped fluid-ejection body having a fine diameter supplied with a solution, ejecting a fluid droplet having an ultra-fine diameter toward a surface of the substrate by applying a voltage having a prescribed waveform to the needle-shaped fluid-ejection body, making the droplet fly and land on the substrate, and solidifying the droplet after the fluid droplet is landed on the substrate; further a three-dimensional structure has a fine diameter comprises droplets having an ultra-fine particle diameter, wherein the structure is grown by solidifying the droplets and stacking the solidified droplets.

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 composite article and its method of manufacture are disclosed. The composite article includes a matrix formed of a mixture of glass particles and a cured polymer, and a layer of cured polymer material that is substantially free of the glass particles, said layer being formed on at least one surface of the cast article whereby the glass particles are not surface exposed on the at least one surface.

Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.

Abstract: A method of preparing a carbon nanotube/polymer composite material is provided. The method includes (a) providing a carbon nanotube-based film and a pre-polymer solution; (b) placing the carbon nanotube-based film at a bottom of a container, and pouring the pre-polymer solution in the container; and (c) polymerizing the pre-polymer solution and simultaneously integrating the pre-polymer solution with the carbon nanotube-based film. As such, a carbon nanotube/polymer composite material, including the polymer-impregnated nanotube layer and an upper polymer layer, is obtained. A multi-layer composite can be produced by essentially repeating this process, using the upper polymer layer as the base layer for the formation of the next layer set thereon.

Abstract: Compositions for forming molded articles, particularly, shells for automotive applications are made up of melt blends of aliphatic thermoplastic urethane elastomer and an olefin-containing block copolymer crosslinked to a gel content of from 5 to 95%. These compositions may be blended to form a powder, pellets, microspheres or minibeads which may then be cast to form air bag door and instrument panel cover skins which may meet automotive deployment and weathering requirements.

Abstract: The present invention relates to an article fabrication system having a plurality of material deposition tools containing one or more materials useful in fabricating the article, and a material deposition device having a tool interface for receiving one of the material deposition tools. A system controller is operably connected to the material deposition device to control operation of the material deposition device. Also disclosed is a method of fabricating an article using the system of the invention and a method of fabricating a living three-dimensional structure.

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 that correspond to the object is provided. The device comprises a machine frame (2, 3, 4, 5); a door (73) that is mounted at the machine frame and is swiveling between an open position and a closed position; a container (25) that can be removed from the device; and a support device (26) that is vertically movable in the container and has an upper side, which forms a building platform (78) on which the three-dimensional object is generated layer wise. A mounting (74) for the container (25) is provided at the door (73) and an attachment (75) is provided at the container (25), which attachment can be brought into an engagement with the mounting (74), so that the container (25) can be moved into the device (1) by closing the door (73) and/or can be moved out of the device by opening the door (73).

Abstract: The present invention is directed towards methods and apparatus for handling powder in a 3D printer. The invention includes a means of transporting powder from multiple sources to a powder dispensing apparatus with minimal user intervention, thus reducing contamination of the 3D printer and surrounding area with loose powder, while also providing a means of improving the recycling of powder for re-use.

Abstract: The invention relates to the use of Fused Deposition Modeling to construct three-dimensional (3D) bioresorbable scaffolds from bioresorbable polymers such as polycaprolactone (PCL), or from composites of bioresorbable polymers and ceramics, such as polycaprolactone/hydroxyapatite (PCL/HA). Incorporation of a bioresorbable ceramic to produce a hybrid/composite material support provides the desired degradation and resorption kinetics. Such a composite material improves the biocompatibility and hard tissue integration and allows for increased initial flash spread of serum proteins. The basic resorption products of the composite also avoids the formation of an unfavorable environment for hard tissue cells due to a decreased pH. The scaffolds have applications in tissue engineering, e.g., in tissue engineering bone and cartilage.

Abstract: A scanning 3-D printing system comprises a printing platform movable in a printing direction and in an indexing direction, the printing platform comprising a printing head configured for dispensing building material while the printing platform is moving in a printing direction one pass at a time, and layer by layer, a roller configured for leveling the dispensed building material one pass at a time, wherein the roller is rotatably mounted on a roller axle, and wherein the roller axle extends over all passes of the printing system and is stationary in the indexing direction, a scraper configured for scraping excess building material off the roller, and a trough configured for collecting the building material scraped off the roller.

Abstract: A process to produce models in layers is described, whereby a first material and then selectively a second material is applied in layers on a building platform and these two application stages are repeated until a desired pattern is achieved. The two materials form a solid if a suitable mixture ratio is used and the first material is a material mixture. The material mixture is at least partially prepared prior to each application stage.

Abstract: A device for manufacturing a three-dimensional object by a layer-wise solidification of a building material in powder form at positions in the respective layers corresponding to the object is disclosed. The device comprises: a container (25) arranged in the device; a support device (26), which can be vertically moved in the container, wherein the upper side of the support device (26) forms a building platform (78), on which the three-dimensional object is generated layer-wise; an application device (27) for applying building material in powder form onto the building platform and a previously solidified layer, respectively; and an energy source (6) that provides a beam (9) for solidifying the building material in powder form. In a region below the container (25) in the device (1) outlets (90) are provided, wherein from each of the outlets (90) a directed flow of a fluid medium escapes in a directed manner to peripheral regions of the container (25).

Abstract: The present invention relates to an article fabrication system having a plurality of material deposition tools containing one or more materials useful in fabricating the article, and a material deposition device having a tool interface for receiving one of the material deposition tools. A system controller is operably connected to the material deposition device to control operation of the material deposition device. Also disclosed is a method of fabricating an article using the system of the invention and a method of fabricating a living three-dimensional structure.

Abstract: A device for manufacturing a three-dimensional object by a layerwise solidification of a building material in powder form at the positions in the respective layer that correspond to the object to be manufactured is provided. A work plane (4) is provided, in which successively layers of the building material in powder form, which are to be solidified, are applied and are partially solidified. An application device (5) for applying a layer of the building material in the work plane or onto a previously solidified layer of the building material has an application surface (53) facing the work plane (4). An adjustment device (59, 60, 54) is provided that is constructed such that an angle (?) between the application surface (53) and the work plane (4) is adjustable.

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: 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: A ribbon liquefier comprising an outer liquefier portion configured to receive thermal energy from a heat transfer component, and a channel at least partially defined by the outer liquefier portion, where the channel has dimensions that are configured to receive the ribbon filament, and where the ribbon liquefier is configured to melt the ribbon filament received in the channel to at least an extrudable state with the received thermal energy to provide a melt flow. The dimensions of the channel are further configured to conform the melt flow from an axially-asymmetric flow to a substantially axially-symmetric flow in an extrusion tip connected to the ribbon liquefier.

Abstract: A method for building a three-dimensional object, the method comprising extruding a build material having a temperature profile between a surface and a central region of the extruded build material in which the surface has a higher temperature than the central region of the build material. The build material comprises a carrier material and nanofibers.

Abstract: A filament drive mechanism comprising a rotatable component comprising a central hole defined at least in part by an internally-threaded surface, and is configured to receive a filament strand through the central hole to engage the internally-threaded surface with the filament strand. The filament drive mechanism further comprises at least one rotation mechanism configured to rotate the rotatable component, thereby allowing the engaged internally-threaded surface to drive the filament strand through the central hole of the rotatable component.

Abstract: A liquefier assembly comprising a liquefier tube, where the liquefier tube comprises a sidewall having an inlet opening configured to receive a filament strand, an outlet opening, and a port disposed through the sidewall at a location between the inlet opening and the outlet opening, the port being configured to provide access for a filament drive mechanism to engage with the received filament strand. The liquefier assembly further comprises a heat transfer component configured to generate a thermal gradient along a longitudinal length of the sidewall between the port and the outlet opening.

Abstract: Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising: a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices; a shuttle to which the printing heads are mounted; a support surface; and a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers; wherein each printing head is dismountable from the shuttle and replaceable independently of the other printing heads.

Abstract: Displacers are used in production of concrete surfaces. The displacers are embodied, for example, as plastic balls or plastic shells and are locked in lattices that are open on one side, preferably downwardly. The modules can then be pressed into a first or second concrete layer that can already contain a first reinforcement mesh. The thus produced semi-finished product can then be covered with a concrete mass during the subsequent finishing process.

Abstract: A pump system comprising a delivery assembly configured to feed a solid material under operational power of a first drive motor, and a screw pump comprising a housing that at least partially defines a barrel of the screw pump, an extrusion tip secured to the housing at a first end of the barrel, a liquefier secured to the housing and intersecting with the barrel, and an impeller extending at least partially through the barrel. The liquefier is configured to receive the solid material fed from the delivery assembly, to at least partially melt the received solid material, and to direct the at least partially melted material to the barrel, and the impeller is configured to drive the at least partially melted material that is directed to the barrel toward the extrusion tip under operational power of a second drive motor.

Abstract: A pill delivery and packing apparatus having a feeder tube for delivering pills is provided. The feeder tube has a helical delivery chute that extends between an inlet side and an exit side of the tube. The delivery chute has a helical inner contour and a rectangular cross section that corresponds to the shape of the pills. The helical delivery chute is configured such that each of the pills rotates while proceeding through the delivery chute, whereby such rotation of the pills prevents jamming of the pills in the delivery chute. Independently extendable pins are used to alternately block and open the delivery chute, thus providing an escapement mechanism for dispensing pills. The tube also has an outer surface defining a helical outer contour that guides a rotatable tray on which pills are disposed. Associated apparatuses and methods are also provided.

Abstract: A method and apparatus for forming three-dimensional objects by laser sintering that includes the use of dense phase pneumatic conveying to internally recycle overflow powder, and to thoroughly blend overflow, recovered and virgin powder to provide a consistent powder feed mix to a laser sintering machine. Overflow powder from the laser sintering machine is recovered and recycled back into the laser sintering machine for reuse. The approach results in a compact and reliable powder recycle system with complete blending and minimum attrition to the handled powder.

Abstract: The invention relates to methods of making articles of semiconducting material and semiconducting material articles formed thereby, such as articles of semiconducting material that may be useful in making photovoltaic cells.

Abstract: The invention relates to a method for applying fluids, especially particle material, on a area that is to be coated, wherein the fluid is applied on the area to be coated in front of a blade when observed from the direction of forward movement of the blade and said blade is then displaced on the applied fluid. The method is characterized in that the blade performs an oscillation similar to a rotational movement.

Abstract: A three-dimensional object forming apparatus forms a three-dimensional object by binding powder particles with a curable liquid. The apparatus includes a powder layer forming unit that spreads a powder to a uniform thickness to form a powder layer. A curable liquid ejection head ejects the curable liquid to the powder layer through an ejection nozzle. A sectional data producing device produces sectional data at each of a plurality of cross sections of a desired three-dimensional object according to shape data of the desired three-dimensional object. A cross-sectional member forming section is also included by which cross-sectional members are formed by ejecting the curable liquid to the powder layer from the curable liquid ejection head according to the sectional data and thus binding the powder layer. The cross-sectional member forming section includes a permeation rate controller controlling the permeation rate of the curable liquid to the powder layer.

Abstract: The present invention provides a method for making an ophthalmic device. In particular, the present invention provides a method for production of a contact lens by means of stereolithography. A preferred stereolithography technique is based on polymerization and solidification of a contact lens forming liquid material by actinic irradiation one layer at a time. In addition, the present invention provides systems and methods for making a contact lens for a specific patient based on the prescription.

Abstract: A two layer material, and method for its manufacture, are disclosed, including an inner and an outer layer, the inner layer formed from an aliphatic urethane elastomeric composition as the layer exposed to view and to the environment and an aromatic urethane elastomer as the inner or backing layer. The layered material may be used to form a skin layer in an automotive air bag door. The layer material may be double cast from microspheres. The inner layer may be formulated to have good heat stability and flexibility, yet not include additives such as UV stabilizer as it may be positioned behind the outer protective layer.

Abstract: The invention relates to a process or a device for the production of a three-dimensional object by layer-wise solidification of a photo-polymerizable resin by means of a planar or essentially planar construction/reference plane, at which the photo-polymerizable resin contained in the liquid material is to be hardened by electromagnetic irradiation, and wherein the material application for the subsequent layer automatically results from the separation of the last hardened layer from the construction/-reference plane, whereby the construction/reference plane is formed by an elastic film. The film is fixed in a frame, and the height position of the frame with the film is adjusted in a basin containing the liquid material such that the pressure of the liquid material compensates the sagging of the film (formation of a negative meniscus), and that the lower side of the film is permanently in contact with the material during the whole construction process.

Abstract: A cementitious material delivery system may include a pump configured to pump cementitious material and an accumulator. The accumulator may be a decoupling accumulator and may contain a reservoir configured to store cementitious material, an accumulator inlet to the reservoir configured to receive cementitious material pumped by the pump, an accumulator outlet configured to deliver cementitious material from the reservoir, and a pressure applicator configured to apply pressure to the cementitious material that is delivered from the accumulator outlet.

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 that correspond to the object is provided. The device has a machine frame (2, 3, 4, 5) and support legs (51) that are mounted at the machine frame and by which the device (1) is supported on a substrate. The support legs (51) are arranged such that a three-point support of the device (1) at the substrate is given and at least two support legs (51) are mounted at the machine frame such that they are adjustable in height.

Abstract: A printing system for creating a three-dimensional object. The printing system includes a plurality of printheads including a first printhead configured to print a first material and a second printhead configured to print a second material. The system includes one or more curing mechanisms for curing the printed materials. The system includes at least one object incorporation device configured to incorporate a non-printed object into the three-dimensional object when partially complete. At least one printhead is configured to print one or more electrical connections to the incorporated object.

Abstract: A mask is used to make an article having two or more layers. The layers are formed from either a paint or polyurethane elastomer composition. The article is made in a mold including a surface defining a mold cavity and having a first and second effect region. For the method, a mask is placed into the mold cavity adjacent the first effect region. Pressure is applied to the mask to retain the mask adjacent the first effect region. A first composition is applied into the mold cavity to form a first layer adjacent the second effect region. The mask is removed from the first effect region. A second composition is applied into the mold cavity to form a second layer adjacent the first effect region. Benefits of pressure applied to a mask are also realized when making the article from a preformed part using the mask outside of a mold.

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 process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent soluble thermoplastic polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

Abstract: Methods of manufacturing an article use three-dimensional printing for a portion of the manufacturing. Three-dimensionally printing is conducted onto a powder bed which contains both organic-solvent-soluble, water-insoluble particles and water soluble, organic-solvent-insoluble particles. The water-soluble particles which may be selected for properties such as size and may include more than one substance. The organic-solvent-insoluble particles may further include at least one substantially insoluble substance such as a member of the calcium phosphate family. Printing may be done using an aqueous binder liquid. After removal of unbound powder, the preform may be exposed to the vapor of an organic solvent which causes the particles of organic-soluble-polymer to fuse to each other. This may further be followed by dissolving out the water-soluble particles, if such particles were present in the powder.

Abstract: A process for mass production of three-dimensional articles made of intermetallic compounds based on titanium and aluminium by an electron beam melting technology. The articles are produced in successive sections from powders of the intermetallic compound with which the articles are to be produced. For each section, melting of the powders preceded by a preheating step is performed.

Abstract: The present invention provides a balloon which achieves diameters greater than 6 mm for securement to a catheter. The balloon includes an elastomeric generally hollow pressure expandable body which exhibits essentially radial symmetry and constant length when expanded under an internally applied minimum working pressure from an uninflated state.

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 in register with 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.