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From Update 69 - 12/7/11 to 3/6/12:

Three-dimensional left-handed metamaterials are the subject of a patent issued to Yamaguchi University (Japan). These negative refractive index materials made by laser sintering are said to make it possible to make a super-lens, capable of imaging objects smaller than the wavelength of light. Numerous advanced applications could result such as use in photolithography or as resonators.
An ultrasonic driller/corer is the subject of a patent application by The California Institute of Technology. EBM and other additive technologies may be used to make parts of the hammering mechanism involved. The device is intended for use in space exploration to punch holes in other planets. See Fig. 3.
A multifunction cardiac simulator and heart valve tester is the subject of a patent application by inventor Shouyan Lee. The device is said to be useful for both research and device testing while being smaller and less complex than previous instruments. See Fig. 4.
Precision Combustion, Inc. is the likely assignee for a patent application by Subir Roychoudhury et al. The adsorption-desorption apparatus described can be used for removing volatile organic compounds (VOCs) and CO2 from a gaseous stream. Another application is for recycling moisture to an astronaut in a space suit. See Fig. 5.
The General Electric Co. is the likely assignee for a series of patent applications concerning injection devices for syngas-fired generators. The devices may be made in a single piece by laser sintering which improves precision and eases field assembly. See Fig. 6.
The near-term practicality of the technology described in a patent application by Frederic G. Commoner is somewhat questionable. Nevertheless, the custom clamps for deep-sea oil containment described are an interesting approach that might be made to work with heavy development. The break or fault is scanned in situ and a precisely fitting clamshell fixture is fabricated to fit over the damaged area. See Fig. 7.

From Update 68 - 9/7/11 to 12/7/11:

Raytheon Company describes the use of additive technology to fabricate complex optical shrouds for sensors in missile nose cones. The shrouds provide both protection and the ability to occlude all but the appropriate radiation, such as the infrared of the exhaust of a targeted aircraft. See Fig. 4.
microTec Gesellschaft fur Mikrotechnologie mbH (Germany) is the assignee for a patent on a method for producing micro-systems that have both mechanical and electronic functions. Over many years the company has developed several photopolymer-based technologies that can produce very high volumes of small complex parts. This patent combines the transfer of electrical components and conductors from a film carrier with those technologies to produce fully-functional systems.
A patent application from Airbus Operations Limited (UK) describes a non-obvious advantage of additive technologies in making and attaching composite parts. By adding a series of pointed prongs during fabrication to a composite part in a specific area of the part, it's possible to provide an integral joining capability. Using conventional nuts and bolts would make it necessary to make the joint layer thicker and heavier to compensate for the required holes to obtain the same strength. See Fig. 5.
Inventors Gojko Obradovic et al (Denmark) describe the use of a resonator channel in a completely-in-canal (CIC) hearing aid. This spiraling tube amplifies the sound and is said to provide the performance of a behind-the-ear (BTE) hearing aid in a much smaller device. See Fig. 6.
Toyota Motor Engineering & Manufacturing has applied for a patent on a heat exchanger for liquid cooling of high power electronic components. While the use of additive methods is unlikely in high-volume hybrid automobiles, Toyota's most likely intended application, there are numerous low-volume applications where the invention could deliver advantages. See Fig. 7.
In its patent application Empire Technology Development LLC describes a microreactor with a curved pathway that is useful for reactions where a product might precipitate out and needs to be separated from a fluid stream. It's said to be useful for a variety of chemical and biological reactions and can also be combined with measurement functions. See Fig. 8.
Northwestern University describes the use of stereolithography to make synthetic mother of pearl (nacre) in its patent. The tough, smooth composite is said to be potentially useful in many applications such as aircraft skin, armor materials, prosthetic coatings and many others. See Fig. 9.

From Update 67 - 6/7/11 to 9/7/11:

Laser sintering and other additive technologies are used to build a small robot according to a patent issued to The National Aeronautics and Space Administration (NASA). The robot is said to be light weight and efficient while having the capability to operate in zero gravity. See Fig. 3.
Deutsches Zentrum fuer Luft-und Raumfahrt e.V. (Germany) is the assignee for patent application concerning a projectile for simulating bird strikes. A jelly-like material center is contained in a laser sintered stabilizer structure. See Fig. 4.
Pratt & Whitney Corp. (Canada) has applied for a patent on a methods of producing electrical conductors. Stereolithography patterns are used to cast complex shapes in copper or aluminum alloys that may be used as power distribution buses. See Fig. 5.
A patent application by John W. Purvis describes a projectile for delivering an incapacitating agent such as tear gas. The agent can be delivered through a barrier such as a wall and the outer sleeve of the device is made by laser sintering. See Fig. 6.
BASF SE (Germany) describes the use of three dimensional printing (3DP) technology from ProMetal RCT to create molded ion exchangers. The devices can serve as catalysts for a wide range of reactions. See Fig. 7.
The Massachusetts Institute of Technology (MIT) describes the use of additive manufacturing to make custom protective articles such as pads for sports use or combat protection, helmet liners and the like in its patent application. There could be numerous medical uses for such devices, as well. See Fig. 8.
Watch out Stradivarius. A stringed instrument fabricated using additive methods can be customized to the needs of a particular player according to a patent application by Yukio Yokoyama (Japan). The sounding box and its vibrational characteristics are of particular interest. See Fig. 9.
Watch out everybody. Inventors Justin C. Yarro et al have had numerous patent applications published this period concerning launchable beverage bottles. The authors have had one or two previous patent applications published for the concept, but this onslaught make it look like they're actually serious. See Fig. 10.

From Update 66 - 3/8/11 to 6/7/11:

Control of fragmentation is a primary consideration in a patent for a warhead issued to Raytheon Company. The device is appropriate for use in rocket-propelled grenades and the like, and its forward-firing fragmentation pattern is intended to reduce collateral damage. A related patent application was also published this quarter. See Fig. 3.
AVIO S.p.A. (Italy) has had a patent application published for a porous rotary separator. The device is used for removing oil from an air stream in a gas turbine. Electron beam melting is used to make the titanium part.
The Boeing Company is the likely assignee for a patent application by John Inman et al. Drill templates made using additive methods are not just for surgery anymore. The device described is designed using the CAD files for the parts to be connected and incorporates vacuum facilities to safely remove drilling debris. Such templates obviously have wider application than aerospace. See Fig. 4.
Three patent applications by Sion Power Corporation describe the use of three dimensional printing (3DP) to make ceramic battery structures. The controlled porosity electrodes formed are said to increase power capacity while improving mechanical integrity. See Fig. 5.
Corning Incorporated is the probable assignee for a patent application by George Beall et al. Three dimensional printing (3DP) is used to make cordierite bodies for diesel and other particulate filtering applications. The filters can incorporate complex internal passageways and the green bodies formed in the process are bonded with animal or plant protein materials in the 3DP process. See Fig. 6.
A method of correcting chromatic aberrations in small, light-weight lenses for digital and video cameras is the subject of a patent application by Canon Kabushiki Kaisha (Japan). A thin lens with a radially-varying refractive index and a number of layers of different materials may be additively fabricated to correct the problem. The description is mainly about the theoretical and mathematical considerations involved.
A patent application by Marvin J. Meeks describes a display rack with a molded skull as a centerpiece. This item is intended for veterans or active members of the military, for example, to display medals, memorabilia and clothing items such as a service hat. Meeks extends the idea by suggesting replacing the skull with a custom sculpture of the individual made by additive techniques. See Fig. 7.

From Update 65 - 12/7/10 to 3/8/11:

Lockheed Martin Corporation has received two patents this quarter for additive fabrication of wing features. One describes a method of making leading edge structures that permits use of a wider range of tough, high temperature materials that are not available in billet form. See Fig. 3.
Making accurate measurements in critical locations in a jet engine is often very difficult because of the extreme nature of the physical parameters involved as well as difficult accessibility. A patent application by The University of Central Florida Research Foundation, Inc. offers a solution for measuring temperature, strain and pressure in deeply buried locations such as within gas turbine blades. Additive fabrication is used to make an embedded RF resonator circuit within the component. As the physical parameter varies, so does the geometry of the resonator which essentially broadcasts its condition to an external measurement receiver.
The University of Maryland has applied for a patent on a controllable miniature mono-wing aircraft. The design is based on winged seeds that flutter to the ground such as those from maple trees. The unit is said to have low power consumption and to be easily deployable in covert operations. It's also capable of steady hovering and is said to be well-adapted to autonomous operation.
See Fig. 4.
While there are many advanced applications for additive fabrication, there are also opportunities for more prosaic ones, as well. A patent application by Conbraco Industries, Inc. is a good illustration. A complex laser sintered separator for a release valve provides quick action to prevent back-flow and contamination in water supply systems. See Fig. 5.
Raytheon uses three dimensional printing (3DP) to form specialized thermoelectric devices. They utilize left over heat from photovoltaic cells to provide an energy conversion device with higher overall efficiency than could be achieved using PV technology alone.
Phantoms are not just for medical imaging applications according to a patent application from General Electric Co. Laser sintering is used to fabricate test targets with an embedded simulated fault. The target can be used in NDT/NDE to confirm testing of pipes and other industrial structures.
Quick fabrication and geometric freedom in creating soft formed hoses and molds are the primary motivations for a patent application from Toyota Motor Engineering & Manufacturing North America, Inc. Many such typically small hoses are often required during automotive development.
Auxetic materials exhibit unusual behavior such as expanding when stretched or the converse. These structured materials with tailored, or even negative and zero poisson's ratios are formed by incorporating complex geometric voids within their volume according to a patent application by Christopher Boyce et al, and likely to be assigned to Massachusetts Institute of Technology. While the authors seem mainly concerned with implant and other biological uses, there could be many additional applications, as well. See Fig. 6.
Jostens, Inc. has been granted a patent for a method of customizing class rings and similar types of jewelry. Text and symbols are mapped onto the curved surface of a ring which can then be turned into a pattern or made directly. See Fig. 7.

From Update 64 - 9/8/10 to 12/7/10:

Airbus (UK) has had a patent application published this quarter for a method of making an airframe component with a built-in damage indication feature. Components incorporating these mechanical fuse-like features would make it easy to determine during inspection if a load specification had been exceeded or if the component was at the end of its useful life. The technique could have much wider application than aircraft. See Fig. 2.
A chip-level bio-analysis system fabricated using a stereolithography-generated mold is the subject of a patent application by Hisao Inami et al (Japan). The system collects micro-organisms from the ambient air and performs gene analysis on them.
Seiko Instruments Inc. (Japan) uses stereolithography to fabricate the holder portions of scanning probe microscope tips according to its patent. The method allows quick mounting of tips without the use of adhesives.
A very interesting geometry for a heat exchanger is the subject of a patent application by Hislop et al (UK and Australia). The thin-walled co-mingled tessellated structure formed by laser melting or a similar process is said to provide better heat transfer while being fast to build with additive fabrication. See Fig. 3.
BAE Systems plc (UK) uses laser sintering to form sonar baffles and backings in its patent application. The porous polyamide parts are said to provide good acoustic properties and to offer great geometric freedom.
Is your Stradivarius too cold or too hot? The solution is a temperature-controlled musical instrument carrying case as described in Gabriel Gunsberg's patent application. Fused deposition modeling may be used to create the interior of the case including housings for active cooling and heating devices. See Fig. 4.
A mechanical clock may be fabricated in its assembled state according to a patent application by Robert Swartz and Peter Schmitt. The weight-driven device seems intended as more of a novelty than as a replacement for conventionally-produced clocks, especially at today's prices. Nevertheless, it would be interesting to examine the economics of batch fabrication of small simple mechanical watches made with additive technologies compared to semiconductor-based timepieces. It might not be quite feasible today for wrist watches, but pocket watches may possibly be made more economically as mechanical devices.

From Update 63 - 6/8/10 to 9/8/10:

GM Global Technology Operations, Inc. has applied for two patents on fuel cell fabrication using photopolymer-based processes. The complex internal geometries of the devices are exposed by masks to create reactant and coolant flow channels. Existing additive fabrication machinery may not be appropriate for production processes, but the basic architecture could be adapted to the application. See Fig. 2.
The Illinois Tool Works Inc. has had a patent application published for the use of additive fabrication to make clich�s for pad printing applications. Clich�s were originally cast from moveable type; copying abilities that gave rise to the common usage of the term. Pad printing is used to mark a vast array of items.
Two patents issued this quarter to Fujifilm Corp. (Japan) and several additional patent applications by other companies illustrate a use that seems to be growing for additive technologies, the fabrication of specialized reaction chambers to aid the production of chemical products. One of the Fuji patents is for micro-channels useful for the stable production of nanometer-scale monodisperse organic pigment fine particles. A second is for a fluid mixing apparatus to be used with such chemical micro-reactors. See Fig. 3.
Inventors Alexander Grigorievich Verkoglyad et al (Russia) have applied for a patent on a capacitive electric current generator. The device provides a low power output from the movement of cellphones, PDAs, GPS or other small portable systems into which it is incorporated. Laser sintering is used to make the capacitors. See Fig. 4.
Disney Enterprises, Inc. has applied for a patent on an interactive animated zoetrope using solid figurines made by additive fabrication. A zoetrope is a device that produces an illusion of motion and was invented in 1834, long before motion pictures. What makes this zoetrope unique is that it is designed to emulate in real-time words spoken by a viewer. The dummy speaks - and he speaks in your voice. See Fig. 5.
Enrico Dini (Italy) has applied for a patent for an additive method of building construction. The system work like a giant three dimensional printer based on 3DP technology. Layers of powder material are deposited by a tractor-like vehicle which subsequently jets a binder into selected areas. Once all the layers are built up and conglomerated the remaining powder material used for support is removed to reveal the structure. Dini is the founder of d-shape (www.d-shape.com) which has already used the method to build some small structures. See Fig. 6.

From Update 62 - 3/9/10 to 6/8/10:

The Boeing Company has been granted a patent for curved extrusions to be used to produce T-chords for an aircraft which are, for example, used to connect the wings to the fuselage. A channel is cut in the extrusion making it easier to form it against a contoured tool, resulting in lower residual and internal stresses. The strength of the extrusion can then be restored in locations where necessary by using additive fabrication to build the part up in those areas. See Fig. 3.
Multiple gradient materials are used to produce a gun barrel according to a patent assigned to Materials & Electrochemical Research Corp. Lighter weight and improved wear and erosion are said to result from the use of a ceramic or other composite inner liner with high-strength, light-weight structural materials such as titanium for the outer barrel. See Fig. 4.
The Aerospace Corp. has applied for a patent on a seamless fluid storage and transport module made by rapid prototyping. The lack of welds, adhesives or fittings is said to minimize the possibility of leaks while providing increased reliability and efficient space utilization. See Fig. 5.
Corning Inc. uses laser sintering to fabricate burner structures for the production of metallic-oxide soot. The soot is used to make crucibles, lenses, tubing and other items. The three-dimensional metal or ceramic burner is resistant to thermal shock and provides an even stream of reactants. See Fig. 6.

From Update 61 - 12/8/09 to 3/9/10:

Complex three dimensional molds made using additive fabrication are essential in making high-torque, low RPM electric motors in a patent issued to Norman Rittenhouse. The motors are said to be useful for such applications as elevators, augers, garage doors and the like, as well as for wind turbine dynamos. See Fig. 3.
Microfabrica Inc. has received a patent for the use of its electrochemical fabrication (EFAB) technology in making such multi-part items as micro-turbines, roller bearings, bushings, and hollow closed structures. Most interesting is that the multiple elements in such devices can be separated from each other by gaps that are smaller than the minimum feature size of the process. See Fig. 4.
Inventors Jose Julian Alvarez Gonzalez et al (Spain) have applied for a patent on an interesting variation concerning additively-fabricated models for testing in wind tunnels. Various geometries of ice that may form on control surfaces are simulated and added to the basic model. This allows data to be gathered for a wide range of possible conditions.
Two patent applications from Novo Nordisk A/S (Denmark) concern the use of a specially-coded drug delivery system that prevents mistakes in giving intravenous and other medicines to patients. A three dimensionally-printed mechanical coding element permits only the correct medication to be attached to the system. See Fig. 5.
Dr. Ing. H.C.F. Porsche (Germany) has applied for a patent on a brake caliper made by laser sintering. It is said to combine high-rigidity with low-weight. See Fig. 6.
Hirschmann Electronics GmbH & Co. KG (Germany) is the likely assignee for a patent application by Othmar Gaidosch (Germany). Low-volume, customized connector shells can be made smaller and less expensively than can be done using injection molding according to the inventor.
Spillage and leakage of the contents of an over-stuffed sandwich onto one's garments, and perhaps the earth itself, will be a thing of the past if the multi-cavity bread form described in Peter Mitchell's patent application rises in the market. This geometrically-complex roll will keep your burger firmly under manual control while tightly securing the layers of applied unguents and other condiments to the assembly. Not only are molds for baking made using stereolithography patterns considered, but the direct printing of futuristic buns is also envisioned. See Fig. 7.

From Update 60 - 9/8/09 to 12/8/09:

General Electric Company has applied for a comprehensive set of patents covering both the making and repairing of gas turbine fuel injection systems. Laser sintering and related methods are the technologies of choice, and the material covers making such parts as fuel nozzles and distributors, mixers, swirlers and combustor components. See Fig. 3.
A complex microfluidic system may be constructed by additive fabrication and used to synthesize polymers with a series of reactions such as an enzymatic cascade. The device may be used to explore metabolic pathways in pharmaceutical design and similar applications. Tufts University is the probable assignee.
It's sometimes surprising to find in what niches the geometric flexibility of additive fabrication offers advantages. One such instance is the subject of a patent application by inventor Mark Slack (UK). Complex channels are required to make explosion-proof speakers and other devices which are required for hazardous locations. See Fig. 4.
A small gas turbine electrical power generating system is the subject of a patent application likely to be assigned to Siemens Energy, Inc. Typical use would be for a system that would be roughly hand-sized. Additive fabrication is used to keep part count down and for its geometric capabilities.
A robust and compliant adaptive grasper for a robot is described in a patent application likely to be assigned to Yale University. What's perhaps most interesting is that the invention takes particular advantage of the ability of Objet Geometries machines to deposit both rigid and flexible materials together. See Fig. 5.
The manufacture of low-volume and customized printed circuit boards is getting increased attention with several patent applications appearing this quarter. In this example, the likely assignee Matsushita Electric Industrial Co., Ltd. (Japan) uses a photopolymer-loaded conductive material exposed by an LCD to form multi-layer boards. See Fig. 6.
Direct writing techniques are one way used to manufacture flat electromagnetic lenses according to a patent application by Penn State Research Foundation. As many as thirty-five or more layers are said to provide good performance in a compact space.
The Boeing Company has applied for a patent on the use of a graded material device formed by laser sintering or spray forming to connect two portions of a structure having highly different coefficients of thermal expansion (CTE) to one another. The work is aimed at attaching nozzles for rockets or jet engine components. See Fig. 7.
Disney Enterprises, Inc. describes the use of fused deposition modeling (FDM) to make molds for silicone skins used with robotic devices such as the company's animatronic theme park characters in its patent application. Savings in costs and manual labor are said to be substantial. See Fig. 8.

From Update 59 - 6/9/09 to 9/8/09:

United Technologies Corp. also has applied for a patent concerning the use of additive fabrication to make turbine disks from multiple materials in order to minimize both centrifugal and thermal stresses. The parts may, for example, be used in auxiliary power units which are run from gas turbine engines. See Fig. 3.
The Aerospace Corp. describes a radial flow solid fuel rocket motor made by stereolithography or other three dimensional printing process in its just-published patent application. The method provides a complex gas flow path and improved oxidizer/fuel ratio throughout the burn while offering better support for the fuel. See Fig. 4.
Inventor Quang-Viet Nguyen has received a patent for a compact and rugged imaging Raman spectrograph. Stereolithography or other 3D printing processes may be used to make the complex device as a single unit, allowing its use in portable chemical analysis applications.
Gowland and Longfield (UK) have applied for a patent on a means of shimming magnetic coils for MRI and similar equipment. The technique is said to result in improved uniformity of the magnetic field and simplified manufacture.
SAAB AB (Sweden) has applied for a patent on a warhead casing. Fabricated using aluminum filled nylon laser sintering materials, the case is claimed to provide better vibration, heat-resistance and other characteristics as well as to avoid collateral damage exposure.
The Boeing Company's patent application for a high density structural health monitoring system obviously applies to aircraft structures, but it could have many other applications as well for buildings, bridges and perhaps even individual small parts in critical applications. A piezoelectric actuator and a sensor are fabricated in close proximity to each other within or upon the structural element to be monitored by additive techniques. Changes in the resonant frequency of the system may be interpreted as changes in the structure. Years ago this was basically the way railway train wheels were inspected. A "car knocker" would prowl about the rail yard hitting each wheel with a hammer. When a wheel didn't sound right, the car was taken out of service. See Fig. 5.
A potentially significant use to which additive fabrication brings considerable advantage is described in a patent application by Jason Moore. Laser sintering is used to manufacture the complex core of a valve for controlling high pressure and high speed fluid flows such as steam, oil, gas or paper pulp. The design of the valve could obviously be adjusted to provide various turn-on or turn-off features. See Fig. 6.
The use of graded-materials can have some non-obvious, but nevertheless significant applications. One of these is the subject of a patent application by Lehigh University. It concerns a transition joint as a welding aid to help join the mild steel of boiler tubes to the high performance steel used in superheaters. There could be many such applications in industry.
The US Navy has applied for a patent to extend its Laser Induced Forward Transfer (LIFT) technology. The technique described can be used to transfer entire chip-level and surface-mount devices according to the authors. The components may be laser-transferred into laser-cut pockets, then interconnected by laser direct writing techniques to create fully-functional circuits.

From Update 58 - 3/10/09 to 6/9/09:

Honeywell International, Inc. has received a patent for a hot gas valve disc used as a switching element in attitude control systems for rockets or missiles. The device uses two layers of material that are each optimized for grain size and/or orientation.
One of the more interesting patent applications published in this category this period is from inventor Zvika Gilad (Israel). This application is a for a pill-shaped TV camera that can be swallowed. microTEC mbH's (Germany) RMPD� technology is used to fabricate the components. See Fig. 2.
Rosemount, Inc. has received a patent for a pressure sensor using near net shape laser sintered ceramics. The integrally-formed device comprises two ceramic cell halves with an internal sintered ceramic diaphragm.
The Boeing Company's patent for a directly-manufactured, self-contained parts kit is likely intended for aerospace applications as far as that organization is concerned. However, there could certainly be many other fields such as medicine and dentistry that may benefit from the basic idea of making both a container and a kit of parts to perform a specific task simultaneously. In addition, building a porous container around the parts would make it much easier to blow or shake away excess build material and not lose any small items in the powder bed, say for example, in laser sintering. See Fig. 3.
Corning Inc. has applied for a series of patents concerning membrane structures and related items that address a wide variety of industrial and environmental filtration applications. Three dimensional printing and other additive processes may be used to make the devices. Water filtration, capture of CO2, scrubbers for smokestacks and absorbents for heavy metals are among the applications described.
Qinetic Ltd. (UK) has applied for a patent on an axial-flow impeller. The design is said to result in much quieter air flow which is accomplished by breaking the large air stream into many smaller streams using a complex channel geometry. Over the course of time it may be possible to exploit this general approach for many applications that could benefit from quieter cooling. Additive fabrication may both aid in the study, and then end up being the only way to manufacture such devices. See Fig. 4.
Sony Corp. (Japan) describes the custom fabrication of micro-beads. Contemplated applications are for processes such as liquid chromatography where the beads might be coated with specific substances to take part in chemical reactions or physical interactions.
The Cabot Corp. describes using direct write technology to customize circuit boards for such applications as displays and automotive electronics in its just-issued patent. Surface mount or other types of standard electronic packages mounted to a PCB are subsequently interconnected with conductors and passive devices formed by additive fabrication to provide customized functions.
Cisco Technology, Inc. has applied for a patent on a light pipe mounting interface made by additive fabrication. As is often the case in electronics, an indicator LED may be mounted on a printed circuit board remotely from a front panel which may be the only place where an operator could observe it. Injection molded plastic light pipes are often used to bring the light to that location, but the tooling costs can be prohibitive if volumes are low. Stereolithography and other additive methods would allow such complicated light pipes to be made economically in small numbers. See Fig. 5.
Craig Gifford and Scott Nielson disclose a method of making customized artificial fingernails in their patent application. Scanned and digitized nail surfaces are used to form the basis for customized nails that may be made using stereolithography or a variety of CNC methods. See Fig. 6.
Nike Inc. describes the use of additive fabrication to make partially-customized footwear in its published patent application. Components that are conventional in nature are joined with personalized components made by rapid manufacturing techniques. Also mentioned are such items as watch bands, hockey equipment, chest protectors, etc.

From Update 57 - 12/9/08 to 3/10/09:

United Technologies Corp. describes a method of making a gas turbine blade having low transient thermal stress. Material properties are graded to compensate for the thickness of the part from its leading to trailing edges. This provides a heating and cooling rate which is uniform throughout the blade resulting in lower thermal distortion. See Fig. 3.
The Boeing Company describes the use of fused deposition modeling (FDM) to fabricate a customized pressure-intensifying tool to aid in the fabrication of composite parts in a patent issued this quarter. It's yet another example of a niche in the process chain of airplane manufacture being filled by direct digital manufacturing.
Aylward Enterprises Inc. has had several previous patents issued for pill-handling equipment making use of additive fabrication in addition to its just-published application. Pills are a good example for which processing equipment must handle a large array similar, but geometrically distinct items. The ability of RP to provide parts that directly interface to such products on short notice without tooling might also prove beneficial for other fields, such as food or hardware.
Murata Manufacturing Co., Ltd. (Japan) has applied for a patent on a photonic crystal band-pass filter for communication applications made by stereolithography. The filter can be tuned over a wide range of frequencies in the GHz region by application of a variable magnetic field.
Northeastern University describes complex meta-materials with embedded dielectric and magnetic particles made by stereolithography. Depending on the geometry the materials can be used as antennas, nano-circuit elements for optics, RF lenses and in many other applications. See Fig. 4.
A patent application by Michael Dunn-Rankin describes a novel writing instrument such as a pencil. A logo or other readable marking is embedded lengthwise in the pencil such that it can be read on the surface of the cone formed by sharpening. Since the marking is embedded throughout the entire length, no matter how small the pencil gets the marking can still be read. See Fig. 5.

From Update 56 - 9/10/08 to 12/9/08:

An active vibration damping system is the subject of a patent issued to The University of Vermont. The main application envisioned is vibration control for electronics, providing damping right at the point where it's required. See Fig. 2.
Antennas and related electromagnetic wave shaping devices made by additive fabrication, usually stereolithography, are appearing more frequently in the IP literature. Several companies have had work published in this field during the period. The picture shows a shaped reflector to provide a substantially uniform wave front from Raytheon Company. See Fig. 3.
The Boeing Company is the assignee for a patent application that describes a more efficient way of connecting large aircraft fuselage sections together. The sections are scanned and assembled virtually. Shims are then created by RP based on the virtual assembly, and used in the actual final assembly. See Fig. 4.
A micro-organ device is described in a patent application from NASA. The interior chambers are designed to contain cell suspensions and are said to be useful for early testing of drugs under closer to physiological conditions.
IN Technology Holding LLC has applied for a patent on contact lenses that can be focused dynamically, much like a patient's biological lens. A fluid reservoir enables the lens surface to change shape under influence of the motion of the eyelid.
The Acushnet Company has applied for a patent on a custom-manufactured golf iron set. The golfer's preferences, playing style, and physical data are used to determine the design parameters.
Three-dimensional food made by three dimensional printing is the subject of a patent application by Wei-Hsiang Lai et al (Taiwan). The possibility of full-color food is discussed as well as simultaneously making the product shipping container itself. See Fig. 5.

From Update 55 - 6/10/08 to 9/10/08:

One of the more interesting hearing aid patents issued this period is assigned to Sound Design Technologies, Ltd. (Canada). It describes the use of custom-fabricated hearing aid vents to reduce feedback at particular frequencies, a fairly non-obvious benefit of the use of additive technology.
Human tissue phantoms that permit training physicians in clinical examinations of the breast and prostate are the subject of a patent granted to Artahn Laboratories, Inc. The devices are said to closely simulate the feel of the real item and are capable of displaying both normal and diseased states. See Fig. 2.
The fused deposition modeling (FDM) process is used to fabricated ultracapacitors in a patent issued to NaturalNano Research, Inc. A slurry containing mineral microtubules is extruded into electrode structures to form very large value capacitors for energy storage and other applications.
Arcam's electron beam melting (EBM) is the method used to fabricate a radio frequency cavity for an electron accelerator in a patent just issued to Radiabeam Technologies LLC. The metal housing has a complex geometry that allows a gentle, discontinuity-free field gradient. Such accelerators are a component used in several types of scientific instruments. See Fig. 3.
The Boeing Company is the likely assignee for three patent applications concerning heat exchangers. The complex geometries are fabricated by electron beam melting (EBM) from Arcam AB, and are said to couple the advantage of requiring no assembly with high thermal efficiency. See Fig. 4.
Sagem Defense Securite (France) describes the use of stereolithography to fabricate covers for electronic devices such as circuit boards which can guide a cooling air flow to specific components or areas. The technique could both improve performance and lower power and flow requirements for fans and other such components, and takes good advantage of the geometric freedom and low-volume manufacturing capabilities of additive technologies. See Fig. 5.
Chanel Parfums Beaute (France) has applied for a patent on a batch-manufactured cosmetic applicator. The complex plastic device could be made by a variety of additive processes, but most likely laser sintering. Additive fabrication avoids a number of assembly steps and allows great geometric freedom. What's most interesting is that this is a high-volume consumer application with no customized features that might well compete with more conventional methods. See Fig. 6.

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

With all the work going on in the field, gas turbine blades are well on their way to becoming the next "hearing-aid" for rapid manufacturing. Their complex geometry and high-value-added nature means that it is becoming increasingly inevitable that additive fabrication will be preferably used for either their tooling or direct manufacture. This quarter, two issued patents to Rolls-Royce Corp. describe a complex mold generated by three dimensional printing which permits directional solidification to produce single-crystal blades. Numerous additional documents in the field were also published this period. See Fig. 3.
Sonitus Medical, Inc. has had additional patent applications published this quarter that describe a novel approach to hearing aid fabrication. One or more extra microphones are mounted to the teeth and receive sounds by bone conduction. The signal may be used to cancel unwanted noise or otherwise improve information processing for the patient. One of the applications this period concerns using the instrumentation to treat tinnitus, the common condition of ringing in the ears. See Fig. 4.
Lawrence Livermore National Security, LLC is the assignee for a device that can be used to quickly determine biological or chemical threats. Specific additive fabrication technologies are not mentioned, but the method of making these "plastic antibodies" is architecturally the same as micro-stereolithography. An inverted microscope is used to expose photopolymer-based substance recognition sites in nano- to micro-scale sizes.
Koninklijke Philips Electronics N.V. (Netherlands) uses fused deposition modeling (FDM) to fabricate seamless enclosures for NMR radio frequency coils in its patent application. Depending on use, such coils can come in intimate contact with a patient and the seamless feature makes them easier and safer to clean.
Lockheed Martin Corp. is the likely assignee for a patent application by Hestness et al. A tool is described for accurately applying epoxy to bond aircraft skins to underlying frames. The tool guarantees that neither too much nor too little material is applied. See Fig. 5.

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

Honeywell International Inc. has received an interesting patent for a small pressure sensor, ostensibly for medical, automotive or industrial applications. What�s most interesting is that Optomec�s Maskless Mesoscale Material Deposition (M3D) (TM) is one method of making the sensor itself, and MicroTEC mbH�s micro-stereolithography is a method of making the package. Combining additive technologies in this way has the potential to become an important factor in many future applications. See Fig. 3.
The Boeing Company describes making a new type of fastener using RP in its just-published patent application. The recess for a tool (slot, star, etc.) in the face of the fastener is filled by a spring-loaded insert when not in use. Such an easy-to-remove fastener provides smooth external surfaces for an aircraft, while not requiring laborious secondary operations such as filling with cement for drag reduction. See Fig. 4.
Siemens Corp. has applied for a patent on a hearing aid with a shell comprising multiple layers that form a battery to power the device. Such a construction is said to considerably decrease the overall volume of the device. See Fig. 5.
Encap Technlogies, Inc. has applied for several patents on aspects of manufacturing electric motors with complex cooling features obtained using additively-fabricated molds. Essentially this is conformal cooling applied to a field other than injection molds. The motors are most likely to be of interest for such applications as hybrid vehicles. See Fig. 6.
Michigan State University has designed a complete gas turbine engine with millimeter cross-sectional dimensions according to their patent application. Local power generation for MMD devices is an obvious application, but the authors also envision the devices as being useful for providing thrust for tiny aerial drones, and when used in the millions able to fly a manned aircraft. See Fig. 7.

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

Siemens AG (Germany) is the likely assignee for a patent application written by Michael Eberler et al. Laser sintering is used to directly manufacture complex gradient coil structures for nuclear magnetic resonance instruments. See Fig. 3.
Caterpillar Inc. has received a patent for the use of additive fabrication in making a complex power system component. Laser powder forming technology is used to make a turbine wheel for a supercharger. Operation at 200,000 RPM requires precision and material integrity. See Fig. 4.
Sonitus Medical, Inc. has had several patent applications published this quarter that describe a novel approach to hearing aid fabrication. One or more extra microphones are mounted to the teeth and receive sounds by bone conduction. The signal may be used to cancel unwanted noise or otherwise improve information processing for the patient. See Fig. 5.
A published patent application by Francis Reininger describes a fiber-coupled artificial compound eye. The system is modeled after the eyes of insects and provides a wide angle view with an infinite depth of field. The structure is made using stereolithography and then coated with aluminum. See Fig. 6, above.
Stereolithography permits the direct fabrication of single piece, light-weight, complex missile igniters without tooling according to a patent issued to the US Army this period.
A published patent application from Lucent Technologies, Inc. uses raised micro-scale features to provide surfaces which reduce the resistance to flow of fluids to very low values. In addition, such hydrophobic surfaces can make biochips, micro-reactors and the like self-cleaning. See Fig. 7.

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

The Goodyear Tire & Rubber Company

See Fig. 3.

DaimlerChrysler AG (Germany) describes extending selective laser sintering and three dimensional printing to carbon particle materials in its published patent application. Porous carbon electrodes are formed which are said to offer great geometric and design freedom for fuel cell applications.
Nuveatix, Inc. has received a patent for a complex IC heat sink made by stereolithography. The device incorporates its own means for forming a matrix of jets of heat transfer fluid for cooling. See Fig. 4.
Solidica's Ultrasonic Consolidation offers some unobvious advantages in a patent application by Frederick Fortson. Metal packaging for sensors and circuitry can be formed around sensitive devices that avoids the heating which would be caused by more typical methods such as welding. See Fig. 5.
Running white-gloved hands over smooth surfaces is often the method used to detect flaws on finely-finished consumer goods like automobiles. What if the gloves had a mind of their own and could amplify small errors for the inspector? Gloves which amplify these small differences contain parts that are geometrically complex and made by stereolithography. See Fig. 6.
Jennifer Lewis and Scott White have applied for a patent on a material containing microcapillary networks. The potential applications are very advanced such as smart materials containing integral sensors, self-healing materials, fluid mixing, etc.

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

SonicBlue Aerospace, Inc. is the likely assignee for a patent application written by Richard Lugg. Additive fabrication is used to make graded-index parts for a hybrid jet/electric turbine engine (called advanced hypersonic magnetic jet/electric turbine AHMJET). The company is a start-up engaged in designing aircraft that will use electrically-driven fans for vertical take-off and landing (VTOL), and gas turbines for forward propulsion. The system is claimed to be considerably more energy-efficient than other schemes. See Fig. 2.
A series of patent applications by Huang et al has been published that hold the prospect of being able to separate, measure, alter or enrich circulating tumor cells or other specific particles from a living organism's blood stream. Specific cells are caused to separate from the main fluid stream by running them through what amounts to a miniature obstacle course. Once free of the main stream they can be worked on with a focused intent that can't be accomplished with more scattershot approaches. The work has profound implications for many medical diagnoses and treatments. See Fig. 3.
Osram Sylvania Inc. describes using stereolithography to make a ceramic bulb for a high pressure discharge lamp. After sintering, the material becomes translucent to allow light transmission. The claimed advantages are fast fabrication without tools. The component could also be made by other additive processes.

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

Low-cost fabrication of satellites is the subject of a patent application by Mosher and Stucker. The authors describe the combined use of several additive technologies such as ultrasonic consolidation and direct writing to make highly-integrated and instrumented satellite systems. See Fig. 3.
EFAB technology from Microfabrica Inc. is described as an appropriate means to make an extremely sensitive and rapid miniature detector for specific proteins and other substances according to a just-issued patent. The tips of numerous micro-tuning forks are coated with different chemical binders for specific substances. As the tuning forks resonate in the presence of target materials that become bound to the tuning forks, their mass changes. A consequent frequency shift can be detected with very great precision. The patent claims a sensitivity of 0.05 picograms. See Fig. 4.
Microfabrica Inc. has had a patent application published for a method of making microtools using its electrochemical fabrication technology (EFAB). The primary use contemplated is multi-functional endoscopic tools, but there could be many industrial uses, as well. Various tools are swung into position and unsheathed at the end of a chain-like arrangement making the device much like a tiny, remote-controlled, Swiss Army knife for surgeons. See Fig. 5.
Patent applications by a Swedish group discuss the use of additive fabrication, particularly selective laser sintering, to make jewelry products from precious metals. Much of the discussion concerns the advantages for producing chain-like and interlinked objects.

From Update 48 - 9/5/06 to 12/5/06:

Road wheels for tracked vehicles are the subject of a patent assigned to GS Engineering, Inc. Additive fabrication is said to allow the production of complex hollow features that optimize weight and inertia. Such wheels might be used, for example, on military vehicles like tanks or on commercial earth-moving equipment. See Fig. 3.
A small implantable glucose sensing system for diabetes treatment and control is described in three patent applications published this period. The work addresses overcoming problems of the human foreign body response which causes materials to be deposited on sensors which interfere with ongoing measurement.
A patent application has been published concerning a microfluidic sperm isolation and insemination device for in vitro fertilization and other applications. Stereolithography may be used to form the complex channels. See Fig. 4.
A sorting device with complex channels can be made using additive fabrication according to a recent patent application. Many uses are foreseen but the main one may be for sorting out sub-standard rice grains from a product stream. See Fig. 5.
Two patents have been applied for on ultrasonic inspection tools and standards. Additive fabrication is said to make it much faster and less expensive to create such devices. Savings can be considerable since a typical composite step wedge standard costs thousands of dollars to fabricate at present. See Fig. 6.
Adrian Marshall (UK) has written a patent application that should make the manufacture of candies and other three dimensional novelty shaped food items like Gummi Bears faster as well as easily customizable. Wheels are fabricated by stereolithography with quadrant sections of the final product shape desired arranged around their periphery. Several such wheels are run together, rather like a rotating extrusion die, to form a continuous stream of feed material into the final desired shapes. See Fig. 7.