Solid freeform fabrication methods

A process for making a three-dimensional article, comprising in the steps of:

• creating an image of said three-dimensional article on a computer, said image including a plurality of segments defining said article;
• generating program signals corresponding to each of said segments in a predetermined sequence;
• providing a mixture of a particulate composition dispersed in a binder;
• feeding said mixture to a dispensing apparatus;
• dispensing said mixture in a flowable fluid state from said dispensing apparatus onto a build platform;
• during said dispensing step, moving said dispensing apparatus and said build platform in response to said programmed signals relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane in a predetermined sequence of movements such that said mixture is dispensed in free space as a plurality of segments sequentially formed so that the last dispensed segment overlies at least a portion of the preceding segment in contact therewith to thereby form said three-dimensional article;
• and
• removing at least a portion of said binder from said article.

A process for making a three-dimensional article, comprising the steps of:

• providing a mixture of a particulate composition dispersed in a binder;
• feeding said mixture to a dispensing apparatus;
• dispensing said mixture from said dispensing apparatus onto a build platform;
• during said dispensing step, moving said dispensing apparatus and said build platform relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said mixture into a three-dimensional article;
• removing at least a portion of said binder from said article by heating said article to a first temperature according to a predetermined heating cycle;
• and
• heating said article to a second temperature greater than said first temperature to at least partially bond said particulate composition together.

A process for making a three-dimensional article, comprising of steps of:

• providing a first mixture of one particulate composition dispersed in a binder;
• providing a second mixture of another particulate composition dispersed in a binder, said second mixture being different than said first mixture;
• feeding said first and second mixtures to a least one dispensing apparatus;
• dispensing said first and second mixtures from said at least one dispensing apparatus onto a build platform;
• during said dispensing step, moving said at least one dispensing apparatus and said build platform relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said first and second mixtures into a three-dimensional article, wherein said first and second mixtures are dispensed in preselected regions of said article;
• and
• removing at least a portion of said binder from said article.