Solid freeform fabrication methods

In a process for making a three-dimensional article incorporating the steps of:

• providing a mixture of a particulate composition dispersed in a binder;
• dispensing the mixture from dispensing apparatus onto a build platform;
• and during the dispensing step, moving the dispensing apparatus and build platform relative to one another to form the dispensed mixture into a three-dimensional article, the improvement comprising:
• Providing as the binder in said mixture a binder comprising a plurality of organic components including a polymer, a wax, an elastomer, and a tackifier.

In a process for making a three-dimensional article incorporating the steps of:

• providing a mixture of a particulate composition dispersed in a binder;
• dispensing the mixture from dispensing apparatus onto a build platform;
• and during the dispensing step, moving the dispensing apparatus and build platform relative to one another to form the dispensed mixture into a three-dimensional article, the improvement comprising:
• Providing in said mixture a binder which includes between about 5 volume percent and about 50 volume percent of a polymer selected from the group consisting of polyvinyl alcohol, polyethylene, polyvinyl acetate, poly (vinyl ethers), poly (vinyl esters), vinyl ester copolymers, ethylene-vinyl acetate copolymers and combinations thereof;
• between about 5 volume percent and about 50 volume percent of a wax selected from the group consisting of paraffin waxes, microcrystalline waxes, synthetic hydrocarbon waxes, oxidized polyethylene waxes and combinations thereof;
• between about 20 volume percent and about 70 volume percent of an elastomer selected from the group consisting of polychloroprene, styrene-butadiene copolymer, natural rubber, neoprene, plyisoprene, polybutadiene and combinations thereof;
• between about 5 volume percent and about 50 volume percent of a tackifier selected from the group consisting of terpene and polyterpene resins, terpene phenolic resins, aliphatic petroleum hydrocarbon resins, rosins, rosin derivatives and combinations thereof;
• and between about 1 volume percent and about 20 volume percent of a plasticizer selected from the group consisting of dibutyl phthalate, dihexylphthalate, triphenyl phosphate, (dipropylene glycol) butyl ether, diethyleneglycolmonoricinoleate and combinations thereof.