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Abstract

A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) operating a multiple-channel material deposition sub-system for dispensing droplets of selected liquid compositions and solid powders at predetermined proportions; (2) providing an object platform in close working vicinity to the deposition sub-system to receive the deposition materials therefrom; and (3) during the material deposition process, moving the deposition sub-system and the platform relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the object. These steps are repeated to deposit multiple layers for forming a three-dimensional shape. These steps are preferably executed under the control of a computer system by taking additional steps of (4) creating an image of the object on the computer with the image including a plurality of segments defining the object and each segment being preferably coded with a color and/or a material composition; (5) generating programmed signals corresponding to each of the segments in a predetermined sequence; and (6) moving the deposition sub-system and the platform relative to each other in response to said programmed signals. Preferably, the system is also operated to generate a support structure for any unsupported feature of the object.

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First Claim