Rapid prototyping process and apparatus therefor

A rapid prototyping process comprising the steps of:

• forming a three-dimensional prototype within a process chamber that generates the prototype on a moveable platform within a build chamber coupled to the process chamber, the forming step comprising the sequential steps of depositing a layer of powered material on the platform, fusing the layer of powered material using a laser beam while simultaneously fusing the layer of powdered material to a preceding layer of powdered material on the platform, and then lowering the platform so as to allow deposition of a subsequent layer of powered material on the platform, the depositing, fusing and lowering steps being repeated until the prototype is finished;
• detaching the build chamber from the process chamber with the prototype remaining within the build chamber while preventing chemical reaction of the prototype;
• and
• cooling the prototype within the build chamber while flowing a nonreactive cooling medium around the prototype.

A rapid prototyping apparatus comprising:

• a process chamber;
• a build chamber detachably coupled to the process chamber, the build chamber comprising a moveable platform reciprocably disposed within the build chamber, means for enclosing the build chamber as the build chamber is being detached from the process chamber, and means for cooling the prototype within the build chamber;
• means for sequencially depositing a fusible material on the platform;
• means for fusing the fusible material on the platform so as to form a prototype within the build chamber;
• and
• means for lowering the platform so as to allow depositing of a subsequent layer of a fusible material on the platform.