Covering All Technology and Application Areas of Additive Fabrication Including:
RAPID PROTOTYPING 3D PRINTING RAPID TOOLING RAPID MANUFACTURING

Technology

From Update 54 - 3/4/08 to 6/10/08:

FCubic AB's (Sweden) patent describes a method similar to three-dimensional printing (3DP), but which is claimed to have the throughput of selective inhibition sintering (SIS). The company recently started providing services to produce small high-resolution metal parts in volumes up to 10,000 or so. See Fig. 1.
Envisiontec GmbH (Germany) is the likely assignee for a patent application describing a continuous generative process for producing a three-dimensional object. The technology is that which is being used in the company's recently-introduced, photopolymer-based Xede™ system. Exposure is by means of a projected DMD image and is done continuously rather than in discrete layers. The system actually "grows" a part. See Fig. 2.

From Update 53 - 12/4/07 to 3/4/08:

Applying additive techniques to the repair of large items such as ship hulls and aircraft is the subject of a patent application by Honeywell International, Inc. The patent is largely directed towards the company’s ion fusion formation method, but this isn’t too dissimilar in architecture from a number of other processes to which it might also be applicable. See Fig. 1.
Georgia Tech Research Corporation has applied for a patent on a method of fabricating nanoscale to microscale structures. A template structure consisting of a natural or synthetic object in one material, is subject to a chemical reaction to convert it into a similarly-shaped object in another material. The starting template might be a natural product such as a diatom, or a synthetic product made by an additive technique such as three dimensional printing. The process is reminiscent of the creation of fossils. See Fig. 2.

From Update 52 - 9/4/07 to 12/4/07:

TNO (Netherlands) has been granted a patent for a method of continuous inkjetting of viscous fluids. High pressure is used to produce discrete uniform droplets of such materials as thermoplastics in the melted state. See Fig. 1.
Hewlett Packard has received a patent for a variation on three dimensional printing which uses translating powder bins as opposed to moving deposition means and stationary bins. It's said to allow the use of components that are currently used in 2D printers and therefore less expensive. See Fig. 2.

From Update 51 - 6/6/07 to 9/4/07:

Eoplex Technologies, Inc. is the assignee for a follow-on patent concerning the company's high volume print-forming system (HVPF). Screen printing is used to fabricate layers of many structures in parallel. Applications foreseen are electromechanical devices, and other small, intricate devices which could compete with micro-stereolithography, EFAB and other such processes. See Fig. 1.
Inventor Bruce Waters is aiming toward additive architectural applications, and has adapted some of the methodology of three dimensional printing (3DP) to the problem. Roving deposition robots deposit layers of ferrocement where walls and architectural features are required and sand in other areas as a support material. Once all the layers are complete and the cement is hardened, the sand can be removed to reveal the building.
Combining EDM (electro-discharge machining) and laser powder forming processes such as direct metal deposition is the subject of a patent application by Jyoti Mazumder et al. The idea is to both additively fabricate a part and precisely finish it in the same setup. The system is said to be potentially capable of sub-micron resolution. See Fig. 2.

From Update 50 - 3/6/07 to 6/6/07:

Hewlett Packard has received a patent on a method of improving the finishes of parts made with inkjet technologies. By controlling the pulse frequency in a drop-on-demand system, drops can be made to fuse together in transit resulting in a continuous stream. See Fig. 1.
A method of electrochemical manufacturing which is analogous to inkjet fabrication has been revealed. Multiple discrete electrolyte jets are used to selectively deposit or etch metals or other materials which are appropriate for electrodeposition. The technology is said to be an improvement on the EFAB process by doing away with the need for masks. The authors also discuss several operating regimens and the fabrication of graded materials.

From Update 49 - 12/5/06 to 3/6/07:

The National Aeronautics and Space Administration (NASA) has received a patent for additive fabrication technology that might be appropriate for making replacement parts in space. The system uses material in wire form which it fuses in layers by an electron beam in a vacuum chamber. See Fig. 1.
A patent application from Lockheed Martin Corp. describes a method of improving the strength of FDM parts by extruding both a thermoplastic base object material and a thermoset plastic matrix around it to provide complementary properties. See Fig. 2.

General Motors Corp. has received a patent for a method of 3D printing of aluminum and magnesium parts. Aluminum and/or magnesium particles are coated with a metal that prevents oxidation and forms an alloy with the main build material.
The University of Texas has applied for a patent on a method of using direct writing inkjet technology to incorporate electronic circuitry within additively fabricated parts. The function may be integrated directly within a stereolithography system.
The next-generation of 3D Systems' photopolymer-based technology has been disclosed this quarter in several patents. One describes the use of an endless transparent belt to provide thin layers of photopolymer at the top of a build stack. Area-wise exposure is done through the belt using a deformable mirror device (DMD) or similar optical method. See Fig. 1.