Process of making a three-dimensional object

In a process for making a three-dimensional object by dispensing a first thermally-solidifiable material in molten form at a first extrusion temperature in a predetermined pattern so as to define the three-dimensional object in coordination with dispensing of a second thermally-solidifiable material in molten form at a second extrusion temperature so as to define a support structure for the three-dimensional object, the improvement comprising the steps of:

• providing as the first thermally-solidifiable material a modeling material comprising a first thermoplastic resin selected from the group consisting of a polycarbonate resin, a polyphenylsulfone resin, and a polycarbonate/acrylonitrile-butadiene-styrene resin, the modeling material having a heat deflection temperature of greater than 120° C.;
• and
• providing as the second thermally-solidifiable material a support material that comprises a second thermoplastic resin and which self-laminates, bonds weakly to the modeling material, has a heat deflection temperature of within about 20° C. of the heat deflection temperature of the modeling material, has a tensile strength of between 5000 psi and 12,000 psi, and which has an amorphous shrinkage characteristic.

An additive process for making three-dimensional objects, comprising the steps of:

• dispensing a modeling material in a flowable state in a predetermined pattern defining a three-dimensional object having overhanging portions that require support during formation, the modeling material comprising a first high-melt flow amorphous thermoplastic resin having a heat deflection temperature of at least 120° C.;
• and
• dispensing a support material in a flowable state in the space beneath the overhanging portions of the three-dimensional object in coordination with the dispensing of the modeling material to form a three-dimensional support structure for the object, the support material comprising a second high-melt flow amorphous thermoplastic resin which self-laminates, bonds weakly to the modeling material, has a heat deflection temperature of within about 20° C. of the heat deflection temperature of the modeling material, and has a tensile strength of between 5000 psi and 12,000 psi.