Method for facilitating the removal of residues from a three-dimensional object formed from multiple layers

A method for facilitating the removal of the residue regions for use in a system for constructing a three-dimensional object by selective attachment of a plurality of sheets of flexible material, each sheet being cut along at least zone contour line so as to subdivide the sheet into at least one object forming region corresponding to the shape of a layer of the object bounded by a corresponding contour of the object and at least one residue region not required in the constructed object, at least part of each object forming region being attached to object forming regions of adjacent layers, the method comprising:

• (a) selectively cutting a plurality of the residue regions of at least some of the sheets along at least one separation line;
• and
• (b) producing selective attachment of at least part of a plurality of the residue regions to the residue regions of adjacent sheets,
• said separation lines and said selective attachment being configured in such a manner as to form, from at least part of the residue regions of a plurality of the sheets, a plurality of residue elements non-rigidly interconnected such that manual removal of each of said residue elements initiates removal of a subsequent one of said residue elements, such that said residue elements circumscribe a residue block such that, after removal of said residue elements, said residue block is readily removable.

A method for facilitating the removal of the residue regions from a side-opening of the object in a system for constructing a three-dimensional object by selective attachment of a plurality of sheets of flexible material, each sheet being cut along at least one contour line so as to subdivide the sheet into at least one object forming region corresponding to the shape of a layer of the object bounded by a corresponding contour of the object and at least one residue region not required in the constructed object, at least part of each object forming region being attached to object forming regions of adjacent layers, the method comprising:

• (a) selectively cutting a plurality of the residue regions of at least some of the sheets along at least one separation line;
• and
• (b) producing selective attachment at least part of a plurality of the residue regions to the residue regions of adjacent sheets, said separation lines and said selective attachment being configured in such a manner as to form from at least part of the residue region of a plurality of the sheets adjacent to the side opening a handle attached to a plurality of said residue portions which lie within the side opening, said handle being exposed by removal of other portions of the residue regions adjacent to the side opening so as to be readily accessible for facilitating removal of the residue portions from within the side opening.

A method for facilitating the removal of the residue regions for use in a system for constructing a three-dimensional object by selective attachment of a plurality of sheets of flexible material, each sheet being cut along at least one contour line so as to subdivide the sheet into at least one object forming region corresponding to the shape of a layer of the object bounded by a corresponding contour of the object and at least one residue region not required in the constructed object, at least part of each object forming region being attached to object forming regions of adjacent layers, the method comprising:

• (a) producing selective attachment of at least part of a plurality of the residue regions to the residue regions of adjacent sheets in such a manner as to form, from at least part of the residue regions of a plurality of the sheets, a plurality of residue elements non-rigidly interconnected such that manual removal of each of said residue elements initiates removal of a subsequent one of said residue elements, such that each one of at least a group of said residue elements assumes a generally flat form extending substantially parallel to the sheets;
• and
• (b) selectively cutting a plurality of the residue regions of at least some of the sheets along at least one separation line, and wherein one of said group of residue elements has a maximum dimension L as measured parallel to the sheets, said residue element being subdivided by said separation lines into at least one strip, said strip having a maximum transverse dimension W no more than a third of said maximum dimension L, such that said strip follows a generally spiral pattern.

A method for facilitating the removal of the residue regions for use in a system for constructing a three-dimensional object by selective attachment of a plurality of sheets of flexible material, each sheet being cut along at least one contour line so as to subdivide the sheet into at least one object forming region corresponding to the shape of a layer of the object bounded by a corresponding contour of the object and at least one residue region not required in the constructed object, at least part of each object forming region being attached to object forming regions of adjacent layers, the method comprising:

• (a) producing selective attachment of at least part of a plurality of the residue regions to the residue regions of adjacent sheets in such a manner as to form, from at least part of the residue regions of a plurality of the sheets, a plurality of residue elements non-rigidly interconnected such that manual removal of each of said residue elements initiates removal of a subsequent one of said residue elements, such that each one of at least a group of said residue elements assumes a generally flat form extending substantially parallel to the sheets;
• and
• (b) selectively cutting a plurality of the residue regions of at least some of the sheets along at least one separation line, and wherein one of said group of residue elements has a maximum dimension L as measured parallel to the sheets, said residue element being subdivided by said separation lines into at least one strip, said strip having a maximum transverse dimension W no more than a third of said maximum dimension L, and said strip follows a reciprocating scanning pattern.

A method for facilitating the removal of the residue regions for use in a system for constructing a three-dimensional object by selective attachment of a plurality of sheets of flexible material, each sheet being cut along at least one contour line so as to subdivide the sheet into at least one object forming region corresponding to the shape of a layer of the object bounded by a corresponding contour of the object and at least one residue region not required in the constructed object, at least part of each object forming region being attached to object forming regions of adjacent layers, the method comprising:

• (a) producing selective attachment of at least part of a plurality of the residue regions to the residue regions of adjacent sheets in such a manner as to form, from at least part of the residue regions of a plurality of the sheets, a plurality of residue elements non-rigidly interconnected such that manual removal of each of said residue elements initiates removal of a subsequent one of said residue elements;
• and
• (b) selectively cutting a plurality of the residue regions of at least some of the sheets along at least one separation line, and wherein each one of at least a group of said residue elements assumes a generally flat form extending substantially perpendicular to the sheets, such that one of said group of residue elements has a maximum dimension L as measured parallel to said residue element, said residue element being subdivided into at least one strip, said strip having a maximum transverse dimension W no more than a third of said maximum dimension L, and said strip follows a generally spiral pattern.