Covering All Technology and Application Areas of Additive Fabrication Including:
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Technology

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

Nederlandse Organisatie Voor Toegepast- Natuurwetenschappelijk Onderzoek (TNO) (Netherlands) has applied for a patent on a photopolymer-based film transfer method of building a part. In this case the film carrying the photopolymer is exposed from below and moved across the part under construction in a wave-like motion after which it is separated from the exposed layer with a rolling action. The method could be quite fast and is also said to use photopolymers economically. See Fig. 1.
Matsuura Machinery Corporation (Japan) has been granted a patent for an improvement to a hybrid method of additive fabrication consisting of laser sintering combined with CNC tooling. The improvement makes for easy removal of the base upon which the part is built and better finishes for the bottom of the part. The company introduced a machine based on the technology during the last quarter. See www.matsuura.co.uk. Dubbed the Lumex Avance-25, the machine offers accuracies of ±0.001 in over the entire build envelope.
Open-source hobbyist system producer MakerBot Industries is the likely assignee for three patent applications by Charles Pax et al. They describe a conveyor system which can be used for building multiple objects in unattended operation. This has been a feature in the past in the company's Thing-O-Matic machines, but has not been continued in its latest offering, the Replicator™. What is most notable is that this is the first instance of a company in the open-source arena walling off its competitors from using a specific development - and at the same time, its customers from developing the invention further. See Fig. 2.

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

Materials Solutions (UK) describes the use of a rotating build plate in laser sintering in its just-issued patent. By rotating the plate according to the geometry of the part being built, it's possible to make delicate, high-aspect ratio parts such as gas turbine blades more accurately and without damaging them during the recoating process. See Fig. 1.
MTT Technologies Ltd. (UK) has applied for several patents concerning laser sintering/selective laser melting (SLM) technology. One patent application is aimed at solving an underappreciated problem in all these related technologies which is the cost of the base upon which parts are built. The disposable base described is said to potentially save as much as $1,700 in the case of a run of making titanium parts as well as the effort of refinishing the base after each use. See Fig. 2.
NextEngine, Inc. is the likely assignee for a patent application by Mark Knighton. The additive technology discussed has both fine and coarse deposition heads, subtractive capabilities such as a milling head, and built-in scanning means. Layer fabrication can be adjusted based on the feedback results obtained during the build from the scanner. See Fig. 3.
3D Systems describes a method for cooling the part cake in laser sintering in its patent application. The cake is physically compressed by moveable walls in the build chamber and nitrogen or another inert gas is forced through the pore volume to rapidly cool it. The compression prevents part distortion and an inert gas blanket is applied during the procedure to prevent discoloration. The process can be carried out within the machine or in a chamber which can be removed from the machine.

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

Objet Geometries Ltd. (Israel) has received several patents for its inkjet-based technology this period. One of the more interesting patents extends use to building color three-dimensional objects. Transparent build material is coated on external surfaces with a white barrier layer onto which colors are applied. See Fig. 1.
Solidscape Inc., now owned by Stratasys, received an additional patent on a method of speeding up its inkjet technology. Drop on demand (DOD) deposited layer boundaries are filled in by continuous spray deposition and then milled flat for the next layer. The potential is to increase the speed of the process by several times.
Inventors Peter Skoglund and Abraham Langlet (Sweden) have had a patent application published that describes a method of making metal parts that have both an amorphous portion and crystalline or nano-crystalline portion. The crystalline portion can be contained within an amorphous metal matrix if desired. Electron beam melting (EBM) is the likely most applicable technology and crystallinity is controlled by the rate of cooling of the material. The net result is to provide parts that have both ductile and very hard regions. The likely assignee is the Swedish Defense Material Administration (FVM). See Fig. 2.

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

The Cornell Research Foundation, Inc. has been granted a patent for a robotic deposition system that includes a tool-changer. This enables the machine to utilize syringes that have different materials, or even to change the deposition method or technology within a single build.
Sony Corp. (Japan) describes a system which combines aspects of stereolithography with area-based technologies such as the Perfactory™ in its recently-published patent application. Exposure is by means of a linearly-scanned laser which is focused on the build stack by a long cylindrical lens through a release film. The lens presses the film against the top of the stack as it's moved along the x-direction for each layer, the film being only in line contact with the photopolymer. This is said to provide much gentler treatment of the film and limit the force required to peel it off the stack. See Fig. 1.
EOS GmbH (Germany) also had two patent applications published this period. One describes the use of high packing densities in the build stack to make parts which can consist of up to 100% of recycled powder. The parts made with recycled materials are said to avoid features like sink marks and in addition the process is sped up. The technique is said to be particularly applicable to PEEK and other advanced materials. See Fig. 2.

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

EOS GmbH has received a patent for a closed build chamber for laser sintering. It uses a cross-flow of air or gas to blow away excess powder in a controlled fashion while the part is slowly being raised and cooled. This is another interesting step in the complete automation of the process. See Fig. 1.
Stratasys describes a method of depositing customized materials for fused deposition modeling in its patent application. Multiple feedstocks are melted and mixed before they're extruded. The feed rate of each material can be independently controlled to adjust the composition.
BEGO Medical GmbH (Germany) describes a method of converting laser sintering and similar technologies from a batch process to a serial one where small items can be fabricated and removed from the system quickly and individually. Instead of applying powder to the top of a build platform across many parts, its applied at 45 degrees to form a part cake only slightly higher than the individual part. The fusing laser is applied to this 45 degree surface to sequentially build layers of single parts serially, each of which is on its own small build platform. See Fig. 2.

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

Sony Corp.'s (Japan) patent this period utilizes both vector laser scanning and a scanned spatial light modulator (SLM) to expose photopolymers. The combination is said to result in fast production of large objects at very high resolution.
Arcam AB (Sweden) speeds the electron beam melting (EBM) process by using two electron beams for exposure. One beam pre-heats the material and the second fuses it. The speeds are synchronized to the propagation speed of the heating zone. This is a preferable arrangement compared to simply using a single beam of higher power which is said to result in stress cracking and similar problems.
Objet Geometries Ltd. (Israel) is the likely assignee for a patent application by Bar Nathan et al. The photopolymer waste disposal system described deposits excess material into small transparent plastic packets where it is cured by flood lights to solidify and neutralize it. The packets are formed by the system from rolls of plastic film. See Fig. 1.
V.G. Kunststofftechnik GmbH (Germany), a service bureau, is the likely assignee for a patent application by Volker and Soeren Griessbach. It describes a method of determining the properties of three-dimensional objects made by additive processes by optically comparing the amount of a dye absorbed into a part over a specific length of time with a known good part as a reference. The method seems intended primarily for laser sintered parts.

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

A patent issued to Innovative Materials Processing Technologies Limited (UK) offers an interesting and possibly more generally-applicable material deposition method. Build material is jetted using electrostatic propulsion through an annular flame. The flame burns off volatile components in the material or initiates a chemical reaction. The patent describes the use of the technique to deposit ceramics or other oxide materials which might not otherwise be possible using jetting technology.
See Fig. 1.
Mikro Systems, Inc. has received a patent for a process that permits making macro-devices with micro-level features. A form of laminated object manufacturing is used to create molds with high levels of detail. The macro devices are cast from these molds. See www.mikrosystems.com.
Stratasys has had a patent application published for a combined process of building three-dimensional models or parts. The object to be fabricated is roughed out using CNC to form a general shape and fused deposition modeling is then used to add the final details to the roughed shape. The work also covers the use of robots to assemble numerous such items into larger products.

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

Evonik Degussa GmbH (Germany) has been granted a patent for an additive fabrication method that is a bit like a cross between three dimensional printing (3DP) and laser sintering. A microwave susceptor is inkjet-deposited in layers within a powder bed, replacing the binder that is commonly used in three dimensional printing (3DP). The entire powder bed is then heated in a microwave oven to adhere the powder. Consumer use is a possible application according the patent.
Stratasys has had a patent application published for a method of layered fabrication that is much like combining FDM with Envisiontec's Perfactory™ process. Extrusion is used to quickly form a layer of photopolymer which is subsequently exposed at high resolution using a deformable mirror device. The intent is to speed the build rate relative to what can be achieved using fused deposition modeling. A special photopolymer is used to provide a self-supporting build stack and unexposed material may be melted away in a post-processing step. See Fig. 1.
CMET Inc. (Japan) has applied for a patent on a method of stereolithography that is said to produce very smooth and fine surface features. A special two-part photopolymer is used. One component of the material is cured upon exposure in the machine by a laser in the usual way while the second component remains in a liquid state. The second photopolymer component effectively fills in the stairstepping formed in the vat during the first exposure, and is post-cured using a flood exposure at a second radiation wavelength. See Fig. 2.

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

Hewlett Packard has received a patent for improving color rendition in three dimensional printing (3DP). The surface of a powder-based part is sealed to keep the colorant from wicking in.
The University of Texas has received a patent for integrating fluid dispensing with stereolithography. The hybrid technology would be capable building direct-write electronic circuitry simultaneously with mechanical structures and mechanisms.
Seiko Epson Corp. (Japan) has applied for a patent on a laminated object manufacturing system. The unique aspect is the use of water-soluble paper as the build material. Inkjet deposition is used to apply a material to selectively make the paper insoluble, and also possibly color it. Support areas are then dissolved away with water in a post processing step. See Fig. 1.
Panasonic Electric Works Co. (Japan) has applied for several patents concerning improvements to the laser sintering/melting process. One patent application describes starting each build layer by applying a fine copper mesh, which is subsequently filled with a different metallic powder. The mesh and powder are then fused together in the laser exposure step. The alloy parts created are said to be more accurate, each layer being held in register by the mesh. See Fig. 2.

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

Microfabrica, Inc. has received a patent on a method of speeding device fabrication by making the top and bottom half of a part simultaneously and then folding over or otherwise combining the structures using built-in alignment features to obtain the final, complete part. See Fig. 1.
Both the University of Washington and Boise State University have received patents for methods of electrochemical fabrication that use either jet or droplet deposition of an electrolytic solution rather than the bath and mask techniques used with Microfabrica's EFAB technology.
Princeton University is the likely assignee for a patent application describing a printing method that might be especially useful for direct writing of electronics, and which might also be of interest in making small three dimensional objects. It's based on electrospinning which permits the drop-on-demand generation of small filaments that can be ten times smaller than the nozzle diameter used to make them.
Optomec, Inc. has applied for a patent on a multiple sheath, multi-capillary aerosol jet. Line widths of less than one micron are said to be achieved.
The Boeing Company describes the use of a purge and sealant cap for a laser sintering build frame in its just-published patent application. This permits the build frame to be removed from the machine so that the sometimes lengthy cool-down process can occur off-line. See Fig. 2.

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

The University of Texas has been granted a patent for multi-material stereolithography. The machine configuration uses a straightforward arrangement of multiple vats and various means of moving a part amongst them. A related patent application from the same group combining other technologies with stereolithography was also published this quarter.
If the technology described in a patent issued to Lockheed Martin Corp. is ever reduced to practice, it may be well be the Holy Grail of additive fabrication. A hologram is projected into a liquid, gaseous or other medium which it solidifies in three dimensions. Holographic movies could be used to create very complicated objects. See Fig. 1.
Stratasys Inc. has applied for three patents on the use of embedded inserts such as RFID tags for part tracking. One of the applications shows a method of combining robotic insertion of the tags with the fused deposition modeling process.
United Technologies Corp. has applied for a patent on what it terms a solid state additive manufacturing system. The method uses a rotating material feed rod held against a substrate to produce frictional heat to melt the material. The process is very much like friction stir welding and is said to overcome problems with melt pool-based technologies especially the ability to deposit fine grain materials. See Fig. 2.

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

The University of Montreal (Canada) is the likely assignee for a patent application from Louis Laberge-Lebel et al. A process that can make free-standing structures is described which uses photopolymer extruded from a guided nozzle. The material is immediately cured by light after emerging from the nozzle. See Fig. 1.
Envisiontec GmbH (Germany) has applied for patents on aspects of its photopolymer-based technology which used deformable mirror devices (DMDs) for exposure. One describes a method of continuously-variable exposure that permits parts to be literally grown. The method is currently used in the company's Xcede™ system.

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

Huntsman Advanced Materials GmbH (Switzerland) has applied for a patent on the technology used in its recently-unveiled Araldite Digitalis rapid manufacturing system. The machine uses a MEMS-based shutter device to cure layers of photopolymer at higher speeds than laser-based vector scanning systems. According to the application, two different wavelengths of exposure light are used: A flash cure at one wavelength is used to hold solidified elements in place, and a second wavelength is used for a longer-exposure final cure. See Fig. 1.
If an inkjet printer system capable of depositing entire buildings appeared in an animated cartoon it might well come out looking like the technology described in a patent application by inventors Paul Bosscher and Robert Williams. A temporary, four-quadrant cable-stay system is erected from which a large bucket containing materials to be deposited is robotically-guided in three dimensions over a cleared section of ground. The system described in this patent application may allow use of existing materials handled in a relatively simple way. See Fig. 2.
Siemens Corp. describes a method of handling the vast data transmission requirements that are associated with the decentralized manufacturing of hearing aids in its patent application. Instead of passing STL files around, the inventors propose sending a more concise point cloud and reference file from which the STL file can be locally generated. While the invention is clearly intended for hearing aids, the problem addressed would be similar for other products and fields which may potentially use distributed manufacturing.

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

Hewlett Packard has received a patent for a method of building stabilizing support structures in powder-based additive fabrication systems such as laser sintering or three dimensional printing. Free-standing structures are built within the powder bed to prevent it from shifting and are said to result in improved accuracy. See Fig. 1.
A process described in a patent application could offer competition for EFAB, micro-stereolithography and other micro- and meso-scale additive technologies. Masks made by photolithography or machining are stacked to form a primary mold. Secondary molds are fabricated from it resulting in volume production of small high-aspect ratio parts. Mikro, Inc. has dubbed the technology Tomo Lithographic Molding (TOMO™).
Technische Universitat Berlin and Voxeljet Technology GmbH (both of Germany) share assignee privileges for a patent application concerning the use of three dimensional printing to fabricate parts which may have, for example, both flexible and rigid sections.

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

Sony Corp. (Japan) has had two patent applications published for improvements to stereolithography. The method combines both laser-based vector scanning with raster-scanned spatial light modulators (SLMs) and is said to enable faster fabrication of large high-resolution parts.
Stratasys describes a method of improving the surface quality of FDM-fabricated parts in its just-published patent application. Parts are suspended in a solvent vapor much like the fashion in which a typical degreasing machine operates. A bead-blasting operation is used to bring the parts to their final finish.
3D Systems has applied for several patents on many aspects of its VFlash™ technology. Particular emphasis is placed on removing uncured materials from the coating web, cleaning brush systems for the web, the cartridge technology, build pads and supports. See Fig. 1.

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.

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

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.