Abstract: An apparatus for formation of a three dimensional object comprising a sealed container; an electron beam subsystem capable of directing energy within said container; a positioning subsystem contained within said container; a wire feed subsystem contained within said container; an instrumentation subsystem electronically connected to said electron beam subsystem, positioning subsystem, and wire feed subsystem; and a power distribution subsystem electrically connected to said electron beam subsystem, positioning subsystem, wire feed subsystem, and said instrumentation subsystem.

Abstract: A method is for producing and applying an antiscatter grid or collimator to an x-ray or gamma detector having matricially arranged detector elements which form a detector surface with detection regions sensitive to x-radiation and/or gamma radiation and less sensitive intermediate regions. In the method, a basic structure is firstly produced for the antiscatter grid or collimator by way of a rapid prototyping technique, through which transmission channels and intermediate walls of the antiscatter grid or collimator are formed which have at least in a first direction a center-to-center spacing which is equal to or an integral multiple of a center-to-center spacing of the sensitive detection regions of the detector. The intermediate walls are coated with a material which strongly absorbs x-radiation and/or gamma radiation in order to finish the antiscatter grid or collimator.

Abstract: The present invention relates to a sinter powder composed of polyamide which also comprises PMMI, PMMA, or copolymers with PMMI, in particular PMMI-PMMA copolymers, to the use of this sinter powder for laser-sintering, and also to moldings produced from this sinter powder. The moldings made from the powder of the invention have marked advantages over conventional products in their appearance and in their surface quality, especially as far as roughness and dimensional stability during selective laser sintering (SLS) are concerned. In addition, moldings produced from the sinter powder of the invention also have better mechanical properties than moldings based on conventional nylon-12 powders, in particular in terms of modulus of elasticity and tensile strength. These moldings also have a density close to that of injection moldings.

Abstract: The invention relates to a rapid prototyping apparatus for the manufacturing of three dimensional objects by additive treatment of cross sections comprising a wholly or partially light-sensitive material, said apparatus comprising at least one light source for illumination of a cross section of the light-sensitive material by at least one spatial light modulator of individually controllable light modulators, wherein at least one light source is optically coupled with a plurality of light guides arranged with respect to the spatial light modulator arrangement in such a manner that each light guide illuminates a sub-area of the cross section. According to the invention, it is possible to obtain a significant simplification of an RP design system, just as the apparatuses designed are essentially capable of creating prototypes of any size, according to the invention.

Abstract: The invention concerns an alveolar structure (1) comprising at least one alveolar zone (2a, 2b) partially delimited by an associated leak tight surface (4a, 4b) . According to the invention, each alveolar zone (2a, 2b) is formed of a plurality of metallic layers (8) superimposed parallel to the associated leak tight surface (4a, 4b), each metallic layer (8) comprising a network of passages (10) opening out on either side of said metallic layer (8). The invention further concerns a method for manufacturing said alveolar structure (1) Application to fuel cells and heat exchangers.

Abstract: A three-dimensional laminating molding device includes ejection heads that eject support material for a support, and an ejection head that ejects mold material for a mold. The support material is sold at room temperature. An inner temperature of the laminating molding device during the laminating molding is controlled to a range of (a melting point of the support material?30)° C. to (the melting point of the support material?5)° C.

Abstract: A method is provided for manufacturing a display with a partition wall to form a luminescent cell on a base 30 of the display. The method includes a step of forming an inorganic micro-powder layer in which an inorganic micro-powder layer is formed on the base; and a step for forming thee partition wall in which the partition wall is formed by irradiating the inorganic micro-powder layer on the base with laser light so as to melt the inorganic micro-powder layer and form the partition wall.

Abstract: A system is disclosed for monitoring and controlling laser cladding process by powder injection in real-time. The invention combines laser cladding technique along with automated direct feedback control to achieve a good quality clad in terms of dimensional and metallurgical characteristics. The system uses optical CCD-based detectors as the feedback system. The optical CCD-based detectors along with a pattern recognition algorithm is used to determine the clad characteristics in real-time. These characteristics are clad's dimensions, solidification rate, and roughness that are fed into a closed loop control system to adjust the laser power and table velocity to produce desired clad quality.

Abstract: Apparatus, systems and methods for use in three-dimensional printing are shown and described. Various embodiments of the invention allow for more precise and controlled delivery of heat to achieve interlayer drying; isolation of the working region from the outside for reasons of cleanliness and in connection with the vapors of organic solvents; better control of the temperature of the working region; better accuracy in the flowrates of binder fluid dispensed; matching of delivered flowrates for multiple dispensers; verification of delivered flowrate or drops; provision for easier changeover of the machine from one powder to another; cleanability; and other needs.

Abstract: A method is for producing an antiscatter grid or collimator for a radiation type, which is formed from a base body of predeterminable geometry having transmission channels for primary radiation of the radiation type which extend between two opposite surfaces of the base body. In the method, the base body is constructed by use of a rapid prototyping technique by layer-wise solidification of a structural material, which is substantially transmissive to the radiation type, under the action of radiation. Inner surfaces of the base body in the transmission channels are coated with a material, which strongly absorbs the radiation type, up to a layer thickness which suffices to virtually completely absorb incident secondary radiation of the radiation type. The opposite surfaces of the base body are not coated, or are aftertreated in such a way that they do not bear a coating or bear a coating of greatly reduced layer thickness made from the material strongly absorbing the radiation type.

Abstract: A method for producing a scattered radiation grid or collimator which, for an incident radiation type, has transmissive regions and nontransmissive regions of predeterminable geometry. First the geometry of the transmissive and the nontransmissive regions of the scattered radiation grid or collimator is set. On the basis of this geometry, a base body is constructed according to the geometry, optionally differing by a particular layer thickness, of the transmissive regions or the nontransmissive regions by a rapid prototyping technique through layer-wise solidification of a structural material under the action of radiation. On the basis of this base body, the scattered radiation grid or collimator is finally completed.

Abstract: A process is provided for producing a three-dimensional object having the steps forming the object (3) in a container (1, 200) arranged within a process chamber (100) on a carrier (4) which can be displaced in the container by sequential selective solidification of layers of a pulverulent material (11) which can be solidified by the action of electromagnetic or particle radiation at positions corresponding to the cross-section of the object in the particular layer, characterised by the step of controlled removal of non-solidified pulverulent material (11) after completing the object (3).

Abstract: The invention relates to a structure assembled from elements, the elements forming an entity with topological interlocking.

Abstract: The present invention relates to a method and a device for selective laser sintering in which powder is introduced in layers into a jacketed design space, forming a powder cake which is consolidated layerwise by laser radiation. The design space is encircled and heated by a jacket heating device.

Abstract: A method for improving production parts produced from a rapid prototyping machine that includes the step of generating a build run that produces output components having production parts and/or iterative improvement specimens. A comparison of the production parts and/or iterative improvement specimens is made to a set of input data that includes dimensions and material characteristics. The comparison produces a resultant data set that includes deviations between the input data and the output components. Build parameters are then tailored for the rapid prototyping machine to reduce deviations between the input data and the output components as compared to previous build runs.

Abstract: A direct-write or solid freeform fabrication method and apparatus for making a device or three-dimensional object.

Abstract: A method of producing an object through solid freeform fabrication, the method including fabricating a support structure about at least a portion of the object by applying a binder or focused energy to a build material.

Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell 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: 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 method for producing a capillary bead array comprises the steps of: dispensing beads into a liquid pool 202, outside a capillary, having a depth of almost the same length as the particle diameter of a bead; leveling the excessive beads by moving a leveling member which is in contact with and relatively capable of be moved to the liquid pool to remove excessive beads that the liquid pool cannot contain; aligning the beads in the liquid pool one- or two-dimensionally; bonding adjacent individual beads to each other; producing a structure 209 having the plurality of beads bonded and aligned one- or two-dimensionally; removing the structure from the liquid pool; and disposing the structure in the capillary formed of soft resin, so that the beads comprising the plurality of beads retaining the one- or two-dimensional alignment can be introduced simultaneously into the capillary.

Abstract: A method for manufacturing ear devices that are individualized for individual. Data of the three-dimensional shape of each individual's area of application for a haring device is provided. Individual shells for the hearing devices are construed by respectively depositing commonly a layer of one of a fluid and a powderous material and solidifying by a laser arrangement in the layer individually shaped layers of the individual shells, thereby controlling the laser arrangement with the data.

Abstract: A magnetic disk is provided which comprises a nonmetallic glass or glass ceramic substrate having one or more under layers, a magnetic layer applied over the under layers, and a hard carbon layer applied over the magnetic layer. A plurality of bumps are formed on the magnetic disk by applying a beam from a near infrared wavelength laser to the surface of the carbon layer.

Abstract: Process for production of three dimensional bodies of particles by a layer buildup process (powder based generative rapid prototyping process), wherein the layer buildup is monitored by an optical control device, which evaluates the light intensity or color differences within and between deposited or hardened particle layers, as well as a suitable optical control device, and further yet, particles or binder liquid particularly suited for optical quality control.

Abstract: Disclosed are methods and systems for selective inhibition of sintering in 3D fabrication. The disclosure provides methods and systems that use selective heating arrangements to selectively sinter areas during fabrication thereby reducing waste improving efficiency.

Abstract: A freeform fabrication method for fabricating a 3-D multi-material or multi-color object from successive layers of a primary body-building powder, at least a modifier material and a binder powder in accordance with a computer-aided design of the object.

Abstract: This invention relates to a device and procedure for the production of a work piece with exact geometry and high surface quality, a form tool in particular. Preferably, the work piece is constructed using a process wherein powder coatings are applied one on top of each other, by means of compaction, said process being computer-controlled. After the powder has been compacted, the surfaces thereof are finely machined in a mechanical manner. During the entire machining process, the work piece to be produced is surrounded with powdery source material.

Abstract: A ceramic article resulting from a chemical interaction between a particulate ceramic material and a ceramic matrix material is described. The ceramic matrix results from at least partial chemical transformation of a precursor material. A chemical bond between the ceramic matrix and the particulate ceramic material is developed during manufacture. The configuration of the ceramic article is developed through use of a rapid prototyping process. A ceramic article comprising different compositions in two or more regions of the article is described. A manufacturing process comprising the steps employed to produce such a ceramic article is also described.

Abstract: A succession of superposed digitized sections of an object are produced from a three-dimensional representation of the object. A powder or a mixture of powders is spread in the form of a fine layer and heated to a temperature close to solid phase sintering temperature of the powder or the mixture of powders. The layer is brought to the sintering temperature by scanning with a laser beam the layer such that a selected part of the powder, corresponding to one of the digitized sections of the object to be produced, is sintered in solid phase by the additional energy supplied by the laser. Additional layers of the powder or the mixture of powders are spread, heated and scanned with the laser beam until all the digitized superposed sections of the object to be produced are obtained.

Abstract: The present invention includes a method for fabricating Si/SiC parts for use in the microelectronics manufacturing industry. The method includes providing a SiC powder. The method also includes providing a polymer binder and mixing the SiC powder and the polymer binder to form a part using an SLS process.

Abstract: A process and a device for producing a three-dimensional object is provided, with which process or device the object is produced by layer-wise solidification of a pulverulent material by sintering of the material at the points corresponding to the cross-section of the object by means of the action of radiation energy. The process comprises the application of a layer of the pulverulent material onto a substrate or a previously sintered layer, pre-heating of the pulverulent material to a working temperature below the temperature at which the powder is sintered and sintering of the material at the points corresponding to the cross-section of the object in the layer, wherein a step of controlled heating of an applied powder layer and of determining the quantity of heat taken up by the powder per (FIG. 3) temperature interval for at least two temperature intervals is carried out.

Abstract: A method for three-dimensional modeling builds up three-dimensional objects in a heated build chamber by dispensing modeling material from a dispensing head onto a base in a predetermined pattern. Physical and thermal separation are maintained between the heated build chamber and motion control components that control the motion of the dispensing head and the base. Thermal isolation of the motion control components from the build chamber allows the chamber to be maintained at a high temperature, and has other practical advantages as well.

Abstract: A process for manufacturing a shaped article, in particular a stereolithographic or a selective laser sintering process, uses radiation energy. A material made of a powder is deposited layer-by-layer onto a surface and is hardened by an application of radiation energy, in tracks, in which the radiation energy impinges the layer to be hardened. The powder in each track is melted entirely or at least partially. Parallel first tracks are applied next to one another at a lateral spacing and without lateral overlap with neighboring first parallel tracks, and second tracks of radiation energy intersecting with the first tracks are applied in order to ensure the hardening of the shaped article. Powder at the intersection points of the first and second tracks is melted at least partially.

Abstract: Methods for improving layered manufacturing techniques to improve an objects' surface properties and shorten manufacturing time for support structures. One aspect of the invention forms surfaces having reduced or no concavities between layers having improved crack resistance. One method deposits alternate, surface improvement material on each layer near the future location of the main material surface, followed by deposition of the main material, the edges of which conform to the previously deposited and solidified alternate material. In this method, the center of the main material layers can be concave rather than the interlayer regions. Another aspect of the invention provides removable structures to support the deposition of main material. The support structures provide support over main material cavities for depositing the material to form the cavity ceilings, while minimizing the time and material required to build the support structures.

Abstract: A three-dimensional object fabricator with an unbound powder removal system is disclosed. The object fabricator forms an object by binding regions of unbound powder in a chamber having the unbound powder removal system operably secured thereto. Unbound powder is removed from the chamber by the unbound powder removal system.

Abstract: A method of fabricating an article, such as a prototype part or a tooling for injection molding, by way of selective laser sintering, using a composite powder system of a metal and/or ceramic powder with a polymer binder comprising thermoplastics and thermoset polymers, and a metal hydride powder to form a “green” article. After removal of unfused material from the green article it is placed in an oven or furnace in a non-reactive atmosphere such as, for example, nitrogen or argon, for subsequent heat treatment to decompose and drive off the binder and sinter the metal substrate particles prior to infiltration by a metal with a lower melting point. During the critical step of decomposing the binders, the metal hydride begins to decompose also and releases an in-situ concentration of hydrogen gas that creates the reducing conditions necessary to thoroughly decompose the polymer fragments so that the hydrocarbon fragments can escape the skeleton structure of the article.

Abstract: This invention provides a process for rapid forming of a ceramic green part. It is based upon an effect, that nano-scaled oxide colloid can be gelled by drying. Slurry can be obtained by mixing the oxide colloid with ceramic powder and dissolved agent. After paving a slurry film on a platform, a focused high-energy beam scans over the surface of said slurry film; the irradiated portion will be dried and build a two-dimensional (2-D) pattern. In addition, another slurry film is paved on the finished 2-D pattern layer. The high-energy beam scans once more on slurry film locally; another 2-D pattern is built. This built pattern can be connected with the pattern beneath it. After multiple repetitions of this procedure a three-dimensional (3-D) part can be formed. Because gelling is an irreversible reaction, the gelled portion of slurry won't be dissolved in water. Therefore, the non-gelled slurry can be separated from the gelled ceramic green part by flushing.

Abstract: A computer-controlled apparatus and method for fabricating three-dimensional articles in layerwise fashion is disclosed. Upon dispensing a layer of a fusible powder, a laser irradiates selected locations of that layer to fuse the powder into a cross-section of the article to be formed in that layer, such that the fused cross-sections fuse together into the article. The laser is controlled in a raster scan fashion across the selected locations of the powder layer. The parallel raster scan lines are separated from one another, centerline-to-centerline, according to a selected pitch, or fill scan spacing value. The positions of the parallel scan lines are determined with respect to a coordinate system at the powder layer, rather than with respect to boundaries of the cross-section being formed; in alternating layers, the parallel scan lines are offset from one another by one-half the pitch.

Abstract: A detoxification process for rendering three-dimensional objects formed by solid freeform fabrication techniques biocompatible for use in long-term dermal contact applications. The process nullifies cytotoxins normally present in objects formed by solid freeform fabrication techniques rendering such techniques as viable for the production of biocompatible devices such as stents, artery valve components, bone implant supports, pacemaker shells, surgical tools, and the like. In one embodiment, a custom hearing aid shell is produced by stereolithography from an acrylate photopolymer resin that was detoxified for long-term dermal contact application. The detoxification process makes three-dimensional objects created by solid freeform fabrication techniques available for products requiring biocompatibility.

Abstract: A process of fabricating aerospace parts using selective laser sintering is provided, wherein the process generally comprises the steps of preparing a powder nylon material, loading the powder nylon material into a laser sintering machine, warming up the powder nylon material according to build warm-up parameters, building the part according to build parameters and part parameters, and cooling down the part according to build cool-down parameters. As a result, parts are produced that are directly used in aerospace structures, which meet the stringent performance requirements of aerospace applications, rather than as rapid prototypes as with conventional selective laser sintering processes. Additionally, specific designs for aerospace parts such as ducts, panels, and shrouds are provided that are produced by the selective laser sintering process.

Abstract: A selective inhibition of sintering (SIS) technique may be used to fabricate a three-dimensional (3-D) dense metal object from a binderless metal powder. A number of layers of metal powder are provided on a build tank. For each layer, regions of the layer are sinter-inhibited, e.g., by depositing a sinter-inhibiting material such as a ceramic slurry, a metal salt, or oxidizing metal particles in the powder using chemicals or a concentrated heat source. Each layer may be compacted before the next layer is provided. A final compact may then be sintered. Unwanted sintered sections may be removed from the compact at boundaries formed by the sinter-inhibited (unsintered) regions, and the object extracted.

Abstract: A three-dimensional object is manufactured by filling and hardening a powder material around a core. A powder material is first filled and layered around the core, and a beam is then selectively irradiated on the layer of powder material to form a hardened layer united with the core. These steps are repeated to form a plurality of hardened layers around the core, thereby manufacturing the three-dimensional object having the core embedded therein.

Abstract: A method of fabricating a three-dimensional heterogeneous small-scale device includes the steps of depositing a fine heterogeneous materials (such as dry powders and biological materials) towards a substrate. In addition, the method includes sintering/cladding the material with a laser so as to produce a pattern. Then, the pattern is micro machined according to the particular design. The depositing step preferably includes providing a feed mechanism having an input to receive the material, an output, and a source of ultrasonic vibration to discharge the material from the output.

Abstract: An apparatus for tacking a multi-lumen tubular assembly together comprises a laser, an optical member and a placement tray for retaining the tubular assembly. A portion of the optical member defines a window that is substantially transparent to laser energy emitted from the laser. The window has a substantially concave shaped surface. The placement tray and the window surface define a processing area for positioning at least a portion of the tubular assembly. The processing area receives the laser energy that is emitted from the laser and passed through the window of the optical member. The tubular assembly is defined by an outer tubular member disposed about at least a portion of at least one inner tubular member. The laser energy transmitted into the processing area is transmitted substantially through the outer tubular member and is substantially absorbed by at least one region of the least one inner tubular member.

Abstract: A detoxification process for rendering three-dimensional objects formed by solid freeform fabrication techniques biocompatible for use in long-term dermal contact applications. The process nullifies cytotoxins normally present in objects formed by solid freeform fabrication techniques rendering such techniques as viable for the production of biocompatible devices such as stents, artery valve components, bone implant supports, pacemaker shells, surgical tools, and the like. In one embodiment, a custom hearing aid shell is produced by stereolithography from an acrylate photopolymer resin that was detoxified for long-term dermal contact application. The detoxification process makes three-dimensional objects created by solid freeform fabrication techniques available for products requiring biocompatibility.

Abstract: Uniform cooling of complex surface shapes in injection mold tooling can be accomplished with cooling channels that conform to the shapes of the mold cavity or mold cone. By conventional methods this can be very difficult to accomplish. By applying methods of material deposition or material sintering, which include but are not limited to, laser metal deposition, where material is deposited on a layer by layer basis, certain cooling or heating passages could be integrated into the manufactured component that follow the contours and profiles of the mold's complex surfaces. These passages would act as internal heat sinks with a much higher surface area for heat transfer than traditional drilled and plugged straight passages. These geometries could also be incorporated into complex geometries such as, but not limited to, turbine blades where the cooling passages can follow the contour of the outer shape, provide a more uniform or controlled heat transfer from the component.

Abstract: Thermally shrinkable films or labels having coated thereon a radiation curable adhesive; and a process for applying thermally shrinkable films or labels to containers comprising the steps of a) coating at least a portion of a thermally shrinkable but unshrunken film or label segment with a radiation curable adhesive; b) applying the film or label to the longitudinal surface of the container; c) subjecting the radiation curable adhesive to a radiation source to effect curing thereof and, d) subjecting the container to heat to shrink the film or label onto the container so as to permanently affix it thereto.

Abstract: A method for forming a three dimensional object, the method including the steps of generating a digital representation of the object, generating a digital representation of a build style lattice having a substantially uniform, conformal tetrahedron structure, overlaying the respective representations of the object and the build style, intersecting the overlaid representations to generate a digital representation of the object incorporating the build style; and fabricating the digital representation of the object incorporating the build style by solid free form fabrication.

Abstract: A method for making freeform-fabricated core composite articles using freeform-fabricated machine. The articles are capable of being utilized as end products rather than prototype models by creating a core having an interior structure to provide strength to the core and to enhance the strength to weight ratio of the article.

Abstract: A maskless stereo lithography method and apparatus for forming a three-dimensional object from a plurality of adhered laminae by exposing successive layers of a photo-curable material to a micro-focused energy beam generated by an array of Fresnel zone plates. The method includes the steps of (A) providing a controllable array of Fresnel zone plates; (B) forming a layer of material adjacent to any last formed layer of material in preparation for forming a subsequent lamina of the object; (C) exposing the material to the micro-focused energy beam to form the subsequent lamina of the object; and (D) repeating the steps of forming and exposing a plurality of times in order to form the object from a plurality of adhered laminae, wherein the array of Fresnel zone plates are employed to focus parallel beamlets of energy beam from a source so that the beamlets converge to an array of focal points at predetermined positions of a lamina in accordance with a computer-aided design file of the object.

Abstract: The present invention provides a tubing assembly having a sidewall having a first layer. The first layer is fabricated from a first polymer blend comprising a first component of a material not thermally responsive to laser beam and selected from the group consisting of polyolefins, ethylene and lower alkyl acrylate copolymers, ethylene and lower alkyl substituted alkyl acrylate copolymers, ethylene vinyl acetate copolymers, polybutadienes, polyesters, polyamides, and styrene and hydrocarbon copolymers. A second component of the blend is a laser responsive material having low solubility in aqueous medium; and the blend being sufficiently thermally responsive to exposure to a laser beam having a wavelength within a range of wavelengths from about 700 nm to about 1500 nm to melt upon exposure to the laser beam for a short period of time. The assembly also has an end cap film covering the fluid outlet.