Abstract: A method for fabricating a three-dimensional (3-D) object is disclosed. The method includes providing a layer of powder material, and selectively depositing bonding inhibitor on selected areas of the layer of powder material. The areas to be deposited with the bonding inhibitor are selected according to a cross-section design of the 3-D object. The method also includes promoting bonding of uninhibited areas of the entire layer of powder material by either sintering or balk deposition of chemical binders. The method further includes repeating the steps of providing a layer of powder material, selectively depositing bonding inhibitor, and promoting bonding until the 3-D object is formed.

Abstract: There is disclosed a method for simulating the appearance of an article having surface texture comprising the step of applying a textured skin having a surface texture to a prototype to produce a textured prototype, thereby to simulate the appearance of the article having surface texture.

Abstract: An apparatus for producing a three-dimensional part by successive layer-by-layer solidification of a solidifiable material, which is solidified at locations corresponding to the cross section of the part is described. The apparatus has a machine housing and a building space provided in the machine housing. An interchangeable container forms a delimiting frame for the material within the building space. The container has a work piece platform. The work piece platform is supported on a supporting device during operation of the apparatus. Preferably, the interchangeable container has a rear side wall with a recess extending vertically, and the supporting device engages the work piece platform through the recess.

Abstract: A method and apparatus for the production of a workpiece of exact geometry and high surface quality, such as, for example, a forming tool, are disclosed. Preferably computer-controlled, the apparatus follows the method of the invention to produce the workpiece by radiation and compacting of nx successive layers of powdered starting material, each subsequent layer being formed on the uppermost surface of the previously formed layer. Following the radiation and compacting of each layer, at least one of the vertical lateral faces of the layer and of one or more underlying layers, all of which are surrounded by excess powdered starting material throughout the process, are mechanically finished, for example by a hobbing process or a peripheral grinding process.

Abstract: A method for producing three-dimensional bodies of a large number of mutually connected layers of a particle-shaped material such as a powder, and where the information of the appearance of each layer is achieved from a computer's CAD-unit or similar. An essentially even particle layer (7) of building material is applied on a support base (6) and on a masking device (9) is arranged a masking pattern in accordance with the information from the CAD-unit, which masking device is led over said particle layer and close to it. A radiation producer (8) is arranged or is led over the masking device (9), whereby the particles which are not covered by the masking pattern are exposed for radiation and thereby are attached to each other. The masking pattern is removed from the masking device and new sequences in accordance with the above are carried through until the three-dimensional body (19) is produced.

Abstract: A method of manipulating data in a method for forming a three-dimensional object layer by layer from an ink jettable, solidifiable material by providing data corresponding to a plurality of polygons defining the outer surfaces of a plurality of three-demiensional objects and providing sets of x, y, and z coordinates corresponding to each layer and identifying x and y coordinates with each z coordinate such that directional values and counter values are determined for each y coordinate in a first set of coordinates generated. A second set of y coordinates are generated according to a formula that permits the determined layers to be processed to form a three-dimensional object.

Abstract: A Method of manufacturing a sintered structure on a substrate is provided. To this end, a particle-charged liquid is provided on the substrate by means of a (multiple print head) ink jet printer. Subsequently, the liquid is evaporated and the particles contained therein are sintered layer by layer. Said layer-by-layer laser sintering enables 3-dimensional products having a relatively high dimensional accuracy to be manufactured. Preferably, evaporation of the liquid also takes place by means of (the same or) a laser. The liquid preferably comprises particles of glass, ceramics or metal compounds in the form of a sol-gel solution or a colloidal sol.

Abstract: A molding tool and a method of fabrication thereof which can reduce the fabrication period remarkably, are disclosed. In particular, a molding tool and a method of fabrication thereof which are most suitable for producing a small lot of plastic molded objects used for preparing prototype parts or the like are proposed. Thin die surface layers (20, 30) each having a predetermined die surface shape (C1, C2) are formed by a stereolithography method using a stereolithography material or a powder sinter molding method using a powder molding material. Reinforcing rib portions (25, 35) are formed integrally with the thin die surface layers by the stereolithography method or the powder sinter molding method on the back surface of the thin die surface layers, respectively. Back reinforcement resin layers (26, 36) are filled integrally in the space of the reinforcing rib portions on the back surface of the thin die surface layers.

Abstract: Disclosed are reinforced metal matrix composites and methods of shaping powder materials to form such composites. Articles of manufacture are formed in layers by a laser fabrication process. In the process, powder is melted and cooled to form successive layers of a discontinuously reinforced metal matrix. The matrix exhibits fine grain structure with enhanced properties over the unreinforced metal, including higher tensile modulus, higher strength, and greater hardness. In some preferred embodiments, an in-situ alloy powder, a powder metallurgy blend, or independently provided powders are reinforced with boron and/or carbon to form the composite.

Abstract: An indirect solid free form scaffold manufacturing technique is provided. More particularly, the present invention provides a set of molds, casting methods, mold removals, and surface modification techniques that are compatible with image-based design methods and with solvent, melt, and slurry casting of polymers and ceramics.

Abstract: A process for producing ceramic molds by sintering selected portions of a ceramic material with a laser beam to form the mold has the following steps:

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: 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 solid freeform fabrication method and related apparatus for fabricating a three-dimensional, multi-material or multi-color object from successive layers of a primary body-building powder, at least a modifier powder and a binder powder in accordance with a computer-aided design of the object, the method including: (a) feeding a first layer of the primary body-building powder to a work surface; (b) operating an electrophotographic powder deposition device to create at least a modifier powder image and a binder powder image in accordance with this design; (c) transferring these powder images in a desired sequence to the first layer of a primary body-building powder; (d) applying energy sources to fuse the binder powder, forming a binder fluid that permeates through the first layer of a primary body-building powder for bonding and consolidating the powder particles to form a first cross-section of the object; (e) feeding a second layer of a primary body-building powder onto the first layer and repeating the ope

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 comprises 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: To provide a three-dimensional molding technique capable of generating a three-dimensional molded article in short time.

Abstract: A computer-controlled apparatus and method for producing metallic parts by laser melting selected regions of a layer(s) of metal powder at a target area are disclosed. The system includes devices for preheating and maintaining a relatively high temperature, e.g. 400° C., of the metal powder so as to join the metal powder together with relatively low laser power, e.g. a 200W CO2 laser. A major powder depositing mechanism with a scraper and a depositing system for a secondary powder are included in the apparatus that allows the powders to be delivered to the target area for selective melting. The metal powder is preheated at either a dispensing cylinder or the target area through thermal conduction and/or is also heated by a heating plate positioned above the platform through radiation. The corresponding machine structures, such as a motion system and a working chamber, are designed to be able to withstand and operated under the high temperature environment.

Abstract: In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects on a layer-by-layer basis by selectively exposing layers of material to prescribed synergistic stimulation including forming portions of a lamina using a first exposure, allowing a time delay, and then applying a second exposure. The time delay is sufficient to allow shrinkage of the material to occur that results from the first exposure. It is preferred that the solidified portion resulting from the first exposure does not adhere to the previously formed lamina. It is also preferred that the portion solidified by this first exposure does not adhere to any boundary region that may have been exposed and adhered to the previously formed lamina. The time delay associated with a given cross-sectional region may be occupied by exposing other cross-sectional regions. The delay may occur between two exposures of overlaying hatch or fill vectors.

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for producing three-dimensional objects by selectively subjecting a liquid or other fluid-like material to a beam of prescribed stimulation. In a preferred embodiment a source of prescribed stimulation is controlled to reduce or inhibit the production of the prescribed stimulation during at least some periods when the prescribed stimulation is not needed to expose the material. In another preferred embodiment, the source of stimulation is controlled to vary the quantity of prescribed stimulation that is produced and allowed to reach the material. In an additional preferred embodiment control of laser output occurs based on a combination of supplying a regulated amount of voltage to an AOM in conjunction with temporary sensing of laser power and a known desired power to attain.

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 process for producing shaped articles are prepared by a process comprising selectively laser sintering a nylon-12 pulverulent material having the following characteristics: Melting point 185-189° C. Enthalpy of fusion 112 ± 17 J/g Solidification point 138-143° C.

Abstract: The present invention provides a method, which infiltrates super-heated material between preheated powder particles and therefore minimizes heat deformation and increases measurement accuracy. A rapid prototyping apparatus in accordance with the present invention comprises powder material spreading means 10, dispensing infiltration material means 20, laser beam scanning means 30, and control means. The powder material spreading means spread out powders 61 on the surface of platform 52 uniformly while moving along the X axis. The powders are the main material of desired products. The dispensing infiltration material means dispense infiltration materials 63 while moving along three axes and the super-heated infiltration materials 64 by laser beam 43 are infiltrated between the powders selectively. The laser beam scanning means preheat the powders by laser beam 42 within the melting point of the powders and super-heat the infiltration material by laser beam 43.

Abstract: Tool having a molding surface is formed from a flowable material (e.g., powder material) wherein the shape of molding surface is formed from a molding process using a master pattern having a surface with a shape substantially the same as the shape of the molding surface to be formed. The tool has at least one thermal control element located within it and spaced from the molding surface where a component used in forming the thermal control element is located within the flowable material prior to solidifying the material. The powder material is preferably a mixture of metals. The thermal control elements include fluid flow paths, heating elements, temperature sensors, and the like.

Abstract: An inorganic binder and a dissolving agent are put into ceramic powder. They are mixed to form a plastic green mixture. Then the said mixture is formed into a thin green layer. Preferably, this thin green layer will be preheated and dried such that the thin green layer will be hardened due to the bonding effect of the inorganic binder. A portion of the thin green layer exposed under a directed high-energy beam is sintered, preferably by a laser beam, to cause ceramic molecules to bond together locally due to heat fusion. By controlling the scanning path of the high-energy beam, a two-dimensional thin cross section of the ceramic part in arbitrary form can be produced. A second thin ceramic layer can be built onto the first thin ceramic layer and bonded to it by the same method. After multiple repetitions of this procedure a three dimensional ceramic part can be fabricated layer upon layer. The green portion, which is not scanned by the high-energy beam, will be removed with suitable method.

Abstract: Methods and apparatus for forming three-dimensional objects from a medium solidifiable when subjected to a beam of pulsed radiation wherein the pulses of radiation are made to occur when the beam is directed to desired pulsing locations on a target surface of the medium. Preferred embodiments of the instant invention include a pulsed laser assembly, including a laser and a pulse generation circuit, a control computer, a plurality of mirrors and mirror encoders. The computer controls the movement of the mirrors which guide the laser beam across the surface of the solidifiable medium. The pulsing of the laser beam is correlated to the position of the mirrors and thus, is not dependent upon time. Pulsing linked to position of beam placement allows controlled and repeatable use of a pulsed beam for the formation of objects.

Abstract: A one-step rapid manufacuring process is used to create three dimensional prototyping parts. Material such as metal, ceramics and the like powder, and wire, and the like, is delivered to a laser beam-material interaction region where it is melted and deposited on a substrate. The melted and deposited material is placed on a XYZ workstation. Three dimensional parts are created by moving the XYZ workstation relative to the laser beam while simultaneously feeding powdered alloys, first in the XY and then in the Z plane. Beam shaping focussing optics can be used to tailor the intensity distribution of the laser beam to the requirements of the deposition layers, and can be used to create parts with desired mechanical or thermodynamic properties. Additional beam splitting and recombining optics can be used to allow powder to be fed at a perpendicular angle to the substrate.

Abstract: A method of fabricating a resilient model of an article of manufacture, such as an earth-boring drill bit body or component thereof, including fabricating the resilient model of the article of manufacture by layered manufacturing techniques. The resilient model may then be employed to cast one or more molds from refractory material. The molds may be used to fabricate the modeled article of manufacture. The invention also includes a resilient, layer-manufactured model of an article of manufacture, such as an earth-boring drill bit.

Abstract: The present invention relates to a method for making a three-dimensional body, the construction of which is realised in layers by a purposeful application of material. According to the invention, two different materials are applied to each layer. One is purposeful applied in line along the outer edge of the three-dimensional object in the corresponding section plane, the remaining surfaces being filled with the second material.

Abstract: A process for making bone implants from calcium phosphate powders is disclosed. This process involves selectively fusing layers of calcium powders that have been coated or mixed with polymer binders. The calcium powder mixture may be formed into layers and the polymer fused with a laser. Complex three-dimensional geometrical shapes can be automatically replicated or modified using this approach.

Abstract: A solid freeform fabrication process and apparatus for making a three-dimensional object. The process includes the steps of (1) positioning a material deposition sub-system a selected distance from a target surface, (2) operating this sub-system to deposit materials onto the target surface by carrying out the sub-steps of (a) operating a multiple-channel fluid phase delivery device of the deposition sub-system for supplying multiple fluid compositions to a small region proximate the target surface and (b) operating a focused energy source to produce a phase change zone at this region, thereby inducing deposition of materials onto the target surface, and (3) during the material deposition process, moving the deposition sub-system and the target surface relative to one another in a plane defined by first and second directions and in a third direction orthogonal to this plane to form deposition materials into a three dimensional shape. These steps are preferably executed under the control of a computer system.

Abstract: An apparatus is described for producing a three-dimensional object from a powder material which includes powder particles and which is solidifiable by exposure to electromagnetic radiation. The apparatus includes a support having a substantially plane support surface for supporting said object, an applying device for applying a layer of the powder material to the support surface, a radiation device for selectively exposing the powder material to electromagnetic radiation at places corresponding to the object and a discharge electrode for generating an electric field for reducing charge differences on the powder particles.

Abstract: An apparatus for rapid prototyping is provided. The apparatus includes a container containing raw material. A working field is defined in the container. A transformation inducing device is arranged above the container. A plate is provided within the container and is movable with respect to the container to move raw material which has been transformed. A least two doctor blades, which are movable over the working field, are provided. The doctor blades are moved via drive elements. At least one of the doctor blades is arranged to create a shadow effect on a shadow region of the working field. The two doctor blades are arranged with respect to each other such that a portion of the working field between the doctor blades and bounded by a shortest closed and continuous contour containing the shadow region is not affected by the shadow effect. This portion of the working field between the doctor blades is ready to undergo transformation after being passed over by only one of the doctor blades.

Abstract: The present invention relates to a laser sinterable thermoplastic powder having a Tg of less than 50.degree. C.

Abstract: A solid freeform fabrication process and apparatus for producing three dimensional parts using layer-by-layer deposition of support powder and part compositional powder, where the deposition is accomplished using electro-photographic powder deposition technology to create a three-dimensional green part. Each successive loose powder layer is deposited directly onto the previously deposited powder layer, which has been compacted or fused to its underlying layer. After all powder layers have been deposited the green part is further processed such that the part compositional powder is fused to create a high-density part while the support powder is easily removed.

Abstract: A method for producing a laminated object repeats a depositing step and an irradiating step alternatively. The irriating step comprises the operations of: covering a deposited layer with a mask having a pattern configuration for penetrating the laser beam; and scanning the lader beam on the desposited layer covered with the mask in such a manner that the laser beam depicts an irradiated continous wave trace being wider than the pattern configuration of the mask, by moving the laser beam in the Y-direction with a Y-rotating mirror, while repeating oscillations of the laser beam in the X-direction with a X-rotating nirror, The laminated object may be a casting mold.

Abstract: A method of producing an object by successive solidification of layers of a powder material is disclosed. The method provides a preformed base plate having a metal plate with a solidified layer of a powder material formed thereon. Then, successive layers of said powder material are applied and solidified on the solidified layer of the base plate to form the object. In further detail, the method for produces a three-dimensional by providing a support and a preformed base plate having an upper surface for supporting the object. The base plate is removably attached to the support. Means are provided for adjusting the elevation of said upper surface. A layer of the powder material is applied to the upper surface of the base plate. The powder material is solidified at points corresponding to a cross-section of the object by irradiation with electromagnetic or particle radiation. Then, the applying and solidifying steps are repeated for completing the object.

Abstract: In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.

Abstract: The present invention is a method which customizes the penetration depth of a heat-fusible powder used in solid freeform fabrication process such as laser sintering. The penetration depth of the heat-fusible powder is customized by combining opaque and transparent powders at a ratio which ensures that the beam contacts a portion of powder beneath its surface, thereby promoting complete layer sintering as well as adherence to previously sintered layers.

Abstract: A method for making a molded refractory article including the steps of providing a mold including a master pattern, the mold and master pattern defining a mold cavity; filling the mold cavity with a mixture comprising refractory particles and a heat fugitive binder; placing the assembly of the mold, master pattern and mixture in a furnace; curing the mixture; separating the mold and master pattern from the cured mixture; removing the binder to form a porous structure, sintering the porous structure to provide a porous refractory article and infiltrating the porous refractory article with a filler metal.

Abstract: A depositing step and an irradiating step are repeated alternately so as to pile solid layers to produce a laminated mold for casting an alloy melt. In the depositing step there is formed a deposited layer of sand coated with a thermosetting resin capable of forming a solid layer upon being irradiated with a laser beam. In the irradiating step, the deposited layer is irradiated with a laser beam to form a hardened solid layer. The irradiating step includes the operations of: distinguishing an outer skin portion from an inner portion of the deposited layer, and emitting a thick laser beam having a large diameter to harden the inner portion of the deposited layer, and emitting a thin laser beam having a diameter smaller than the thick laser beam to harden the skin portion of the deposited layer.

Abstract: A method and apparatus for forming a laminated object using a laser-discharging means a laser beam, a material capable of forming a solid layer by receiving the laser beam, and a mask for interrupting the laser beam. The method includes the steps of: forming a layer of the material on a surface, covering the material with the mask, and discharging the laser beam onto the material covered with the mask to solidify the material and form the solid layer on the surface. The above cycle is repeated to produce a laminated object. The method and the apparatus are characterized in the adjusting at least one of a distance from the laser-discharging means to the mask and a distance from the mask to the material, so that the extent of the laser beam is adjusted and the dimension of the laminated object is adjusted.

Abstract: Solid objects are formed in an imagewise layering process in which components of a dispersion are homogenized to form an alloy. Imagewise exposure of the layers to radiation to form an alloy permits separation of the exposed, homogenized regions from non-exposed, non-homogenized regions. As each layer is formed and imagewise homogenized, contiguous layer regions are bonded together to form a homogenized, three-dimensional object which may be separated from surrounding dispersion.

Abstract: Novel compositions and methods are provided for use in the stepwise, layer by layer fabrication of three-dimensional objects, in which a build material contains a metal having a covalent bond to a non-metal, and the layers are processed to produce the three-dimensional object at least in part through a chemical reaction which alters the covalent bond of the metal. In a first aspect of the invention the build material includes a metal that is covalently bound to a polymeric precursor. In another aspect of the invention, the build material includes a metal, Me, that is covalently bound to a first ligand, L.sub.1. Following deposition of the build material, the first ligand undergoes a redox reaction with a second ligand, L.sub.2, thereby breaking the covalent bond of the metal. In more preferred embodiments of this class, L.sub.1 and L.sub.2 react to form a gas, and the metal reacts to form an oxide such as MeSO.sub.x, MeNO.sub.x, MeCO.sub.x and so forth.

Abstract: This invention provides a heat transmitting pipe and a heat transmitting plate which are capable of greatly improving the heat transfer efficiency of a conventional finned heating pipe and a convention heating plate. Copper oxide powder is deposited in a vapor phase onto a cellular synthetic resin coated with an adhesive beforehand. Thereafter, a copper plate with the same metal powder deposited thereon is placed on one surface of the metal powder-bearing cellular synthetic resin and is brought into lightly pressed contact with the surface by a roll press or the like, to thereby form a laminated article. Subsequently, the cellular synthetic resin is burnt off in a combustion furnace, to thereby produce a cellular metal material of the copper oxide on the copper plate. Further, the cellular metal material is reduced and sintered in a reducing atmosphere such as that of a hydrogen reduction furnace, to thereby produce a cellular copper material which is provided with the copper plate on one surface thereof.

Abstract: In order to achieve a homogeneous density distribution in a layer to be solidified of a three-dimensional object produced by laser sintering a laser beam is passed across the surface of the layer to be solidified, whereby the travelling speed of the beam varies as a function of the length of lines of a line pattern.

Abstract: An apparatus for producing an object by stereolithography is provided with a tank (1) receiving a bath of liquid or powdery material which can be solidified by action of electromagnetic radiation. In known manner the apparatus comprises a support (4) for positioning the object relative to the surface (3) of the bath and a device (8) for solidifying a layer of the material (3) adjacent to the surface using electromagnetic radiation. In order to allow a precise adjustment of the layer thickness the apparatus comprises a supplying device (51) for supplying the solidifiable material (3), the supplying device extending transversely across the tank and having a discharge opening (53) at its bottom side in operational position, a channel extending in the interior thereof and communicating with the discharge opening (53), the channel being connected at one point with a pump (63) through a conduit (62).

Abstract: A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making high resolution objects utilizing low resolution materials which are limited by their inability to reliably form coatings of a desired thickness. The formation of coatings of such materials is limited to a Minimum Recoating Depth (MRD), when formed over entirely solidified laminae, which is thicker than the desired layer thickness or object resolution. Data manipulation techniques result in layers of material (and laminae) of the object being categorized as non-consecutive primary layers (laminae) and secondary layers (laminae) positioned intermediate to the primary layers (laminae).

Abstract: In a method for producing a three-dimensional object (6) wherein the object is produced by successive solidification of individual layers (6a, 6b, 6c, 6d, 64) of a liquid or powderous material (3) by action of electromagnetic radiation (8, 10) and a supporting structure (20, 21) for supporting the object (6) is co-solidified together with the object (6), the supporting structure (20, 21) is decomposed in a three-dimensional fashion into an inner core region (22) an an outer envelope region (23) and the irradiation is varied for producing different characteristics of both regions.

Abstract: Solid objects are formed in an imagewise layering process in which components of a dispersion are homogenized to form an alloy. Imagewise exposure of the layers to radiation to form an alloy permits separation of the exposed, homogenized regions from non-exposed, non-homogenized regions. As each layer is formed and imagewise homogenized, contiguous layer regions are bonded together to form a homogenized, three-dimensional object which may be separated from surrounding dispersion.