Method for constructing three dimensional bodies from laminations

A method of manufacturing an integral three-dimensional object from laminations, comprising the steps of:

• developing a contour representation of a three-dimensional object;
• fabricating a set of first sheets of an uncured inorganic powder material;
• cutting each of said set of first sheets to a desired shape, each of said first sheets when cut being a contoured layer representing a cross-section of the three-dimensional object;
• fabricating a set of second sheets of a fugitive material;
• cutting each of said set of second sheets to a desired shape, each of said second sheets when cut being a contoured layer representing an empty area in the cross-section of the three-dimensional object;
• and,
• stacking said contoured layers of said first and second sheets in a desired sequence such that one contoured layer of said first sheets and one contoured layer of said second sheets are stacked at a time;
• securing said contoured layers to each other;
• and,
• sintering the inorganic powder material of said contoured layers to form an integral body from said contoured layers.

A method of manufacturing an integral three-dimensional object from laminations, comprising the steps of:

• fabricating a plurality of first sheets of a first material composition;
• fabricating a plurality of second sheets of a second material composition;
• cutting each of said first sheets to form a contoured layer representing a cross-section of the three-dimensional object and to form a waste material;
• cutting each of said second sheets to form a contoured layer representing a void in a cross-section of the three-dimensional object and to form a waste material;
• discarding the waste material of said first and second sheets;
• stacking said contoured layers of said first and second sheets in a desired sequence to form a stack of contoured layers;
• laminating said stack of contoured layers;
• and, subsequently securing said contoured layers of said stack to each other to form an integral three dimensional object, said step of securing including a step of combusting said contoured layers of said second material;
• and,
• removing residual material resulting from said combusting step by applying a mechanical action to the integral three dimensional object.

A method of manufacturing an integral three-dimensional object from laminations, comprising the steps of:

• developing a contour representation of a three-dimensional object;
• fabricating a set of first sheets of an uncured inorganic powder material;
• cutting each of said set of first sheets to a desired shape, each of said first sheets when cut being a contoured layer representing a cross-section of the three-dimensional object;
• fabricating a set of second sheets of a fugitive material;
• cutting each of said set of second sheets to a desired shape, each of said second sheets when cut being a contoured layer representing an empty area in the cross-section of the three-dimensional object;
• stacking said contoured layers of said first and second sheets in a desired sequence such that one contoured layer of said first sheets and one contoured layer of said second sheets are stacked at a time;
• securing said contoured layers to each other;
• combusting at least a portion of said contoured layers of said second sheets and sintering the inorganic powder material of said contoured layers of said first sheets to form an integral body from said contoured layers;
• forming a remaining portion of said contoured layers of said second sheets into a granular material;
• providing an aperture in the integral body formed from said contoured layers;
• and,
• applying a mechanical action to the integral body formed from said contoured layers so that the granular material can fall out through said aperture.