Fast three-dimensional modeling method and device

A system for applying a uniform layer of a viscous material in a layerwise fashion in a rapid prototyping apparatus, the system comprising:

• a means for providing a working field for forming layers of the viscous material;
• a means for supplying a volume of the viscous material adjacent the working field, the viscous material not flowing when a shear stress of less than about 20n/m2 is applied;
• a means for applying at least a portion of the volume of viscous material over the working field to form the uniform layer, the means for applying the viscous material comprising at least one recoater blade and at least one rotating roller to form the uniform layer when the recoater blade and roller are driven in a coating direction;
• a drive mechanism for moving the recoater blade and roller in the coating direction;
• and
• a means for rotating the roller, the roller contacting the volume of viscous material and establishing a log of viscous material circulating along a looping path about the rotating roller, the recoater blade being downstream from the roller when driven in the coating direction, the recoater blade being in communication with the log of viscous material to channel the material circulating along the looping path when the recoater blade and roller are driven across the working field in the coating direction.

A rapid prototyping apparatus for forming a three-dimensional object from a viscous material in a plurality of layers, the apparatus comprising:

• a means for providing a working field for forming layers of the material;
• a means for supplying a volume of the material adjacent the working field;
• a means for applying at least a portion of the volume of material over the working field to form a uniform layer of the material, the means for applying the material comprising at least one recoater blade and at least two rotating roller to form the uniform layer when the recoater blade and roller are driven across the working field in a coating direction;
• a drive mechanism for moving the recoater blade and rollers in the coating direction;
• a means for rotating the rollers, the rollers contacting the volume of material and establishing a log of material circulating along a looping path about both rotating rollers, the recoater blade being downstream from the rollers when driven in the coating direction, the recoater blade being in communication with the log of material to channel the material circulating along the looping path when the recoater and rollers are driven in the coating direction;
• and,
• a means for transforming the uniform layer of material to form a layer of a three-dimensional object prior to forming another uniform layer of material.