Abstract: A method is provided for rapid prototyping of complex structures, such as complex bone structures and internal neural and cardiovascular pathways. The method involves loading the triangles from a polygonal mesh computer model of a 3D object having one or more internal void spaces, converting the triangles to voxels, separating the voxels of the model into watertight pieces, and printing the pieces using a 3D printer such as a ZPrinter™. The method allows realistic internal void space representation through removal of excess powder from printing which would otherwise be trapped in the whole object and also allows the application of a resin to internal surfaces which may provide realistic internal object density useful for medical and other applications. Pegs and holes may also be added to and subtracted from the pieces to allow for assembly of the printed object. A system and computer program product is also provided.

Abstract: Methods and techniques of using 3D printers to create physical models from image data are discussed. Geometric representations of different physical models are described and complex data conversion processes that convert input image data into geometric representations compatible with third party 3D printers are disclosed. Printing templates are used to encapsulate complex geometric representations and complicated data conversion processes from users for fast and simple 3D physical model printing applications.

Abstract: A direct-metal deposition (DMD) processing stage and a 5DOF (degree of freedom) dry micro-EDM (mEDM) stage are integrated to provide the submicron scale resolution necessary for the ultra-precision processing of work pieces. The DMD processing stage includes optical feedback for dimensional control utilizing a high-power, fiber-coupled diode laser with fast response time and small beam parameter product. The electrical discharge machining (EDM) stage is a dry EDM stage using an inert gas with appropriate dielectric properties to perform the surface finishing operations. The system further includes one or more surface treatment operations to obtain a desired level of surface hardness or wear resistance and/or to minimize the distortion induced in treating the surface.

Abstract: Described herein are bioprinters comprising: one or more printer heads, wherein a printer head comprises a means for receiving and holding at least one cartridge, and wherein said cartridge comprises contents selected from one or more of: bio-ink and support material; a means for calibrating the position of at least one cartridge; and a means for dispensing the contents of at least one cartridge. Further described herein are methods for fabricating a tissue construct, comprising: a computer module receiving input of a visual representation of a desired tissue construct; a computer module generating a series of commands, wherein the commands are based on the visual representation and are readable by a bioprinter; a computer module providing the series of commands to a bioprinter; and the bioprinter depositing bio-ink and support material according to the commands to form a construct with a defined geometry.

Abstract: The disclosure provides a method to construct and physically join near-net shaped structural building blocks into a composite part using an interfacial reaction-activation mechanism.

Abstract: A set of two-dimensional layers is determined based on a digital three-dimensional model. An image corresponding to each of the layers is rendered on each of a corresponding number of sheets of at least partially transparent material. The sheets of material are assembled together to produce a three-dimensional structure corresponding to the digital model.

Abstract: The present invention provides methods allowing the use of selective laser powder processing techniques for the production of medically acceptable prosthetic dental frameworks. The frameworks produced according to the present invention have high grade mechanical properties as well as a high accuracy.

Abstract: Methods and systems for weight-based identification of three dimensional (3D) printed parts. Various embodiments disclosed herein may permit reliable processing of 3D printed parts to effectively scale a 3D printing service to large volumes of orders for 3D printed parts.

Abstract: A 3D printer that can use ABS-plus plastic material deployed in the battlefield for printing polycarbonate, or rubber components individually or in combination to create component parts comprised of two or more materials. A library of autonomous vehicles will be created utilizing the standard components and the 3D printer. These libraries will include a variety of light weight UGVS, fixed wings UAVS, quads rotors, hex-rotors, UGS, etc. The library will also include a variety of standard payloads that would be interchangeable from platform to platform. Each model in the library will provide the operator with a performance envelop of the printed system. A submission and approval process will be created for new devices. A common control architecture for controlling the devices will be forced on every model in the library.

Abstract: Powder spreaders suitable for use with layered manufacturing processes are disclosed in which a strip of flexible material of a width which spans the powder bed is used to spread, level, and, optionally, compact deposited powder to form a layer of the powder bed. The strip surface moves relative to the deposited powder it is spreading as the working portion of the strip, i.e., the portion of the strip that is in contact with the powder, traverses across the powder bed so that it can provide lift to the powder in front of it and, optionally, compaction to the powder below it. The working portion of the strip can be configured to have its leading and trailing surface contours to be different from one another, and, optionally, to have these contours and its bottom edge contour be independently adjustable. Layered manufacturing systems comprising such powder spreaders are also disclosed.

Abstract: An additive three-dimensional fabrication process is improved by controlling deposition rate to obtain surface textures or other surface features below the nominal processing resolution of fabrication hardware. Sub-resolution information may be obtained, for example, from express metadata (such as for surface texture), or by interpolating data from a source digital model.

Abstract: A printing system is provided having at least one printhead for printing material to create a printed product, and an object incorporation device that incorporates inorganic semiconductors into the product being printed while the at least one printhead prints the product.

Abstract: The production of a hearing aid housing shell or ear mold that can be worn in the ear should be simplified and improved. For this, a prefabricated component, such as a frame for holding an electronics module or a receiver adapter, is positioned in a rapid prototyping instrument. There, the component is integrated into the housing shell or ear mold by the subsequent production of the housing shell or ear mold. This avoids connecting the component to the housing shell or ear mold in a further method step after producing the housing shell or ear mold.

Abstract: The invention provides systems and methods for manufacture of a non-homogeneous article using a 3D voxel-based model of the article and a rapid prototyping device. Use of a voxel-based model provides processing advantages and offers improved realism of the manufactured object with regard to non-homogeneous (i) color, (ii) translucency, and/or (iii) hardness, for example.

Abstract: In order to effectuate proper construction of prosthetic devices during surgery, a device that will shape the prosthetic device from the patient's own tissue has been contemplated. Although ear surgery requires exacting measurements because of the size that is involved is discussed, many other types of artificial devices can be manufactured during a number of different types of procedures to include orthopedic and dental prosthesis. Many different types of tissues may be used and a computer with associated software will enable a milling machine to manufacture the required prosthetic device at the time of the procedure.

Abstract: A three-dimensional object fabrication apparatus is disclosed. A housing encloses a work area having at least two distinct zones including a fabrication zone and an assembly zone. Digital data defining geometry for a three-dimensional object to be fabricated is passed via an interface to a processor within the housing. A fabrication mechanism in the fabrication zone to fabricates sub-elements where each sub-element corresponds to a portion of the object substantially consistent with the digital data. An assembly mechanism in the assembly zone joins the sub-elements in relative alignment to form the object defined by the geometry.

Abstract: Methods, apparatuses, computer program products, devices and systems are described that include accepting one or more blood vessel sleeve dimensions based on blood vessel data from an individual; and making a rapid-prototyped blood vessel sleeve at least partly based on the one or more blood vessel sleeve dimensions.

Abstract: The present invention provides an RP system which can directly use hot melt polymers for fabricating porous 3D construct for cell culture and other biomedical applications based on a CAD design. To realize the direct use of polymer hot melt, the RP system uses a hot melt chamber which is mounted on a robotic dispensing ann or a XYZ motion control system. The hot melt chamber is equipped with a delivery mechanism to force the molten polymer passing through a nozzle. The extruded polymer thin filament deposits onto the positions according to the computer generated model, in a layer-by-layer fashion, similar to FDM. The present invention can use any type of thennal plastic polymer pellets, beads, particles, which are suitable for extrusion and injection molding, as well as composites of two or more different thermal plastic polymer blends, inorganic particle/thennal plastic composites.

Abstract: A method and system for producing a dental implant surgical guide is disclosed. A patient-specific virtual model is generated using image data specific to a patient and virtual dental implants. The virtual model aligns the image data with the virtual dental implants using modeling software. A virtual mold is generated from the virtual model, and a physical mold is generated from the virtual mold. The physical mold is covered with a thermoplastic sheet via a thermoforming process. Excess thermoplastic material is trimmed off after the thermoforming process to produce a thermoformed piece. Metal tubes corresponding to each the virtual dental implants are placed onto the physical mold denoting the position, trajectory, and depth of the one or more virtual dental implants. A dental implant surgical guide that contains the thermoformed piece with the one or more tubes is produced.

Abstract: A method of forming an article in a layer wise manufacturing process from a computer software file representing the article includes dividing the file into sub files in dependence of the size or other characteristics of features of the article to be created, applying a process characteristic selected independence on a characteristic feature to each sub file and manufacturing the article in accordance with the subfiles.

Abstract: Systems and methods disclosed herein employ various modes of material deposition and material removal to build a complex, three-dimensional structure upon a rotating base. The systems and methods may be usefully employed to fabricate geometrically and aesthetically accurate dental articles from digital models.

Abstract: Systems and methods are provided for fabricating products on demand. In some embodiments, a manufacturable model, which may include information about a three-dimensional representation of a product to be fabricated, is received by a user of an electronic system and may be validated by the electronic system. A prototype of the product can be generated based at least in part on the manufacturable model, and the manufacturable model and/or the product can be made available for selection by other users of the system. The product may be fabricated based at least in part on the manufacturable model using, for example, a three-dimensional printer, and may be delivered to users of the electronic system.

Abstract: A conveyor or other transport mechanism is provided to support multiple, sequential builds from a three-dimensional fabrication machine. The conveyor may be heated/cooled, coated, or otherwise treated to assist in adhesion during a build, as well as removal of objects after a build. Each fabricated object may be automatically removed from the conveyor as the conveyor moves in order to restore a buildable surface for fabrication of additional objects.

Abstract: The systems and methods disclosed herein employ a combination of digital three-dimensional modeling and rapid fabrication technologies to provide pre-indexed, pre-registered, and/or precut components for articulated dental models. Dental articulators and components of dental models as described herein use a positioning key to encode positional information for components of the dental model, and/or a reference grid on mounting surfaces to enforce local accuracy of fabricated parts against a fixed reference array.

Abstract: A method is set forth for making a computer model of patient's jaws on the basis of digital information. Digital data about the jaws, teeth, soft tissues and artificial teeth is joined in computer space to create aesthetic and functional plans for the removal of teeth, shaping of supporting bone and placement of dental implants. Artificial teeth and pre-manufactured prosthetic devices are made and attached to the dental implants at the time of surgery. The aesthetic and functional position of artificial teeth is determined prior to surgical removal of natural teeth and the ideal position of implants and the proper form of the remaining bone are determined prior to surgery. Surgical guides used to shape bone, record occlusal orientation and position dental implants are manufactured using computer milling or layered manufacturing.

Abstract: A method of producing a flexible vessel model for simulating a surgical operation, which is a three-dimensional model being capable of reproducing an aneurysm or narrowing occurring in the artery or vein based on CT/MRI image data of a patient obtained in practice and thus allowing vascular therapy trainings and preoperative simulations, with the use of a precise lamination modeling machine, wherein a vascular model having an affected part is fabricated by using a lamination technique together with a supporting material for sustaining the shape of the three-dimensional model during the fabrication in the precise lamination modeling machine and, after the completion of the fabrication by the lamination machine technique, the supporting material is removed.

Abstract: A method and system for estimating context offsets for run-to-run control in a semiconductor fabrication facility is described. In one embodiment, contexts associated with a process are identified. The process has one or more threads, and each thread involves one or more contexts. A set of input-output equations describing the process is defined. Each input-output equation corresponds to a thread and includes a thread offset expressed as a summation of individual context offsets. A state-space model is created that describes an evolution of the process using the set of input-output equations. The state-space model allows to estimate individual context offsets.

Abstract: A three-dimensional model built with an extrusion-based digital manufacturing system, and having a perimeter based on a contour tool path that defines an interior region of a layer of the three-dimensional model, where at least one of a start point and a stop point of the contour tool path is located within the interior region of the layer.

Abstract: A network of fluid dispensers is configured such that a Host controller may exchange information with local dispensers, and where local dispensers may exchange information with each other. The information may be dispensing processes, information regarding quality and reliability, problems and/or helpful information, and applications. The information may be exchanged in real time during fluid dispensing where any issues may be shared and resolved quickly even in remote locales. The applications may be developed at a local dispenser or at the Host and then shared throughout the network. The operating systems may include application software development tools, and the applications may include: monitoring deliver schedules and materials inventories; automatic issuing of purchase orders; training broadcasts; implementing industry standards for validation and approval.

Abstract: A mechanism is provided for converting a set of single-layer design rules into a set of split-layer design rules for double patterning lithography (DPL). The set of single-layer design rules and minimum lithographic resolution pitch constraints for single exposure are identified. The set of single-layer design rules comprise a first plurality of minimum distances that are required by a set of first shapes in a single-layer design. Each of the first plurality of minimum distances in the set of single-layer design rules are modified with regard to the minimum lithographic resolution pitch constraints for single exposure, thereby forming the set of split-layer design rules. The set of split-layer design rules comprise a second plurality of minimum distances that are required by a set of second shapes and a set of third shapes in a split-layer design. The set of split-layer design rules are then coded into a design rule checker.

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: The present invention provides a number of innovations in the area of computational process control (CPC). CPC offers unique diagnostic capability during chip manufacturing cycle by analyzing temporal drift of a lithography apparatus/ process, and provides a solution towards achieving performance stability of the lithography apparatus/process. Embodiments of the present invention enable optimized process windows and higher yields by keeping performance of a lithography apparatus and/or parameters of a lithography process substantially close to a pre-defined baseline condition. This is done by comparing the measured temporal drift to a baseline performance using a lithography process simulation model. Once in manufacturing, CPC optimizes a scanner for specific patterns or reticles by leveraging wafer metrology techniques and feedback loop, and monitors and controls, among other things, overlay and/or CD uniformity (CDU) performance over time to continuously maintain the system close to the baseline condition.

Abstract: A system and method for use in constructing a prosthesis/complete restoration that obtains a digital dentition model, such as a 3D geometric surface model or a 3D volumetric image model, processes the digital dentition model to form a virtual model, forms a virtual mold including a digital prosthesis and/or complete restoration, and uses the virtual model to construct the prosthesis/complete restoration. Processing circuitry, such as a programmed server, can be used to obtain the digital dentition model and form the virtual mold. A rapid manufacturing device can be used to construct the prosthesis/complete restoration.

Abstract: A method of placing a dental implant analog in a physical model for use in creating a dental prosthesis is provided. The physical model, which is usually based on an impression of the patient's mouth or a scan of the patient's mouth, is prepared. The model is scanned. A three-dimensional computer model of the physical model is created and is used to develop the location of the dental implant. A robot then modifies the physical model to create an opening for the implant analog. The robot then places the implant analog within the opening at the location dictated by the three-dimensional computer model.

Abstract: In one embodiment, the present invention provides a method for forming battery tray for holding cylindrical cell batteries. The method includes forming a battery try including a base support having a generally flat bottom surface and multiple adjacent cylindrical cavities are formed within the base support, using a circle packing algorithm to form the cylindrical cavities. The adjacent cavities each have at least some interstitial cylindrical riser wall structures formed with a predetermined height to hold the cylindrical cell batteries. In another embodiment, the present invention allows for packing maximum energy density per layer. This allows lifetime and power output of a battery powered device to be optimized and/or increased.

Abstract: A device for the production of a three-dimensional object made of solidifiable material having at least one processing unit (11) for the processing of the solidifiable material into a liquid phase to discharge the material from a material reservoir (12) via a discharge unit (13) in the direction of a construction space (17) in the form of intermittent drops (15). The conditions required for this can be satisfied (FIG. 2) via the closing mechanism featuring a plastic malleable solid body joint (24).

Abstract: A sporting equipment cover consisting of a custom three-dimensional printed figurehead attached to a cover portion. The printed figurehead is fabricated from a three-dimensional scanned image of an individual using a three-dimensional ink jet printing process. The printed figurehead can be coated with one or more layers of a clear protective coating to increase the longevity of the printed figurehead. A mounting flange is formed about a mounting edge of the three-dimensional printed figurehead. The mounting flange is attached to the cover portion using a mounting bracket, a mechanical fastener, or other fastening interface. The cover portion can be designed to cover any sporting equipment, including golf clubs, racquets, etc. Alternatively, the printed figurehead can be a complete head and attached using a bobble head styled interface.

Abstract: Methods for generating supports (30) for parts (50) produced by solid freeform fabrication (“SFF”) are disclosed. The method includes defining a plurality of layers (L) that make up the part, and for each layer, determining those regions (R) that require support. The method also includes merging the regions for the different layers (L) into one or more common regions that require support, and providing at least one support for each of the one or more common regions. The result is that fewer supports are used as compared to conventional SFF fabrication methods.

Abstract: Three-dimensional models are produced using a sheet material made of water-soluble paper. Each layer of the sheet material is made severable along the contour lines of the three-dimensional model by discharging water onto each layer of the sheet material. A coloring solution is discharged when each layer is deposited to color the sheet material. After the deposition is completed, the unnecessary parts of the sheet material can be pulled away to complete the three-dimensional model. Alternatively, by discharging a setting solution onto each layer of the sheet material, each layer of the sheet material in the section of the three-dimensional model can be insolubilized, and a color setting solution can be discharged to color and set the colored parts. After the deposition is completed, the deposition can be immersed in water to remove the sheet material that was not insolubilized and complete the three-dimensional model.

Abstract: For enabling fast, customer-specific and precise matching of a hearing device's directional characteristic, a hearing device having a signal processing unit for performing a processing algorithm is provided, with at least one design-related parameter of the hearing device having been made available to the signal processing unit and with the signal processing unit performing the processing algorithm based on the design-related parameter of the hearing device. It should be considered as especially advantageous in the case of the inventive hearing device that a processing algorithm can be performed particularly precisely and customer-specifically based on the provided design-related parameters of the hearing device.

Abstract: A system for imaging one or more items produced by rapid prototyping may include, but is not limited to: control electronics including a memory containing a plurality of data sets representing design items; a user interface coupled to the control electronics and operative to select one or more of the data sets representing design items and operative to receive user view selections; a rapid prototyping device coupled to the control electronics and responsive to the selected one or more data sets representing design items to produce physical items; a positioning mechanism operable to accept the produced physical items from the rapid prototyping device and to position the produced physical items in a field; and an image capture device responsive to the received user view selections electronics to selectively image at least a portion of the field corresponding to the received user view selection.

Abstract: A system and method for use in constructing a prosthesis/complete restoration that obtains a digital dentition model, such as a 3D geometric surface model or a 3D volumetric image model, processes the digital dentition model to form a virtual model, forms a virtual mold including a digital prosthesis and/or complete restoration, and uses the virtual model to construct the prosthesis/complete restoration. Processing circuitry, such as a programmed server, can be used to obtain the digital dentition model and form the virtual mold. A rapid manufacturing device can be used to construct the prosthesis/complete restoration.

Abstract: A method of producing an object by sequentially printing layers of construction material one on top of the other, the method comprising: providing the construction material at a first lower temperature; flowing the construction material through a heated flow path in a flow structure to heat the construction material and delivering the heated construction material to a heated reservoir in a printing head; and dispensing the heated construction material from the reservoir to build the object layer by layer.

Abstract: Disclosed herein is a device adapted to make a solid object. The device has a surface rotatable around an axis of rotation, and an applicator adapted to apply over at least one portion of the surface a material used to make the solid object. The applicator and the surface are displaceable relative to each other in a direction transverse to the axis. Disclosed herein are also methods of determining instructions for the device.

Abstract: There are many inventions described and illustrated herein. In one aspect, the present invention is directed to a technique of, and system for simulating, verifying, inspecting, characterizing, determining and/or evaluating the lithographic designs, techniques and/or systems, and/or individual functions performed thereby or components used therein. In one embodiment, the present invention is a system and method that accelerates lithography simulation, inspection, characterization and/or evaluation of the optical characteristics and/or properties, as well as the effects and/or interactions of lithographic systems and processing techniques.

Abstract: A method of controlling the flow of unbound powder in a build chamber. A build surface for receiving the powder is provided, with the build surface including a first plate defining holes and a second plate defining a plurality of openings spaced apart and offset from the plurality of holes in the first plate. The second plate is disposed below and spaced from the first plate. A vacuum source is provided below the build surface.

Abstract: A method by which an orthodontic appliance is automatically designed and manufactured from digital lower jaw and tooth shape data of a patient provides for the scanning of the mouth of a patient to produce a three-dimensional digitized model of the shapes of the patient's teeth and their positions in the patient's mouth. The appliance is automatically designed according to the final design, which also can be interactively modified and approved by the orthodontist, with the computer recalculating the effects on the treatment as a result of the doctor's changes. Brackets are fabricated as an integrated set, either by cutting slots therein or by building the brackets in layers. Three-dimensional custom jigs are automatically made to exactly position the brackets on a patient's teeth.

Abstract: The present invention relates to a compensation method for structural deformation occurring during construction of a super tall building, which includes the steps of: selecting horizontal and vertical members predicted to require compensation for horizontal and vertical deformation amounts; calculating deformation amounts based on the casting time of structural concrete for the selected horizontal or vertical members; determining compensation amounts based on the casting time of structural concrete for the selected horizontal or vertical members; calculating deformation amounts of the selected horizontal or vertical members up to and subsequent to the non-structural construction processes; determining compensation amounts by process of the selected horizontal or vertical members; and constructing the selected horizontal or vertical members by floors.

Abstract: The invention relates to a method for the production of a biologically active prosthetic device for the reconstruction of bone tissue comprising the steps of: a CAT (Computerized Axial Tomography) scan of the patient and obtaining a three-dimensional electronic model (1) of the part of the bone and of a bone defect (2) to be reconstructed; production by prototyping of a prototype resin model (3) of the area of the patient's bone involved, forming of a model (4), of the patient's bone defect to be reconstructed; construction of a netative mould (5), production of a ready sintered ceramic semi-finished product with controlled and interconnected porosity, said semi-finished product being made with dimensions and shape slightly larger than the bone defect; mechanical processing and manual finishing of the sintered semi-finished product, to obtain the precise dimensions and shape of the bone defect, the invention also relating to the prosthetic device obtained using the method described above.

Abstract: The present invention relates to a system and method of transforming an inconsistent 3D (three-dimensional) model of one or more 3D objects into a valid printable 3D model, said method comprising: (a) receiving an input model file and/or receiving modeler data, giving rise to an input 3D model having one or more parts; (b) analyzing said input 3D model and removing its one or more inconsistencies; (c) thickening the one or more parts of said 3D model, while preserving their functionality; and (d) unifying the union of interior volumes of said one or more parts, thereby removing self intersections and/or intersections between the two or more parts, giving rise to a valid printable 3D model.