System and method for rapid fabrication of arbitrary three-dimensional objects

Abstract

A three-dimensional object fabrication apparatus is disclosed. A housing encloses a work area having at least two distinct zones including a fabrication zone and an assembly zone. Digital data defining geometry for a three-dimensional object to be fabricated is passed via an interface to a processor within the housing. An efficient material supply mechanism sources the build material.

What is claimed is: 
     
         1 . A three-dimensional object fabrication apparatus comprising:
 a housing enclosing a work area;   an interface in the housing to receive digital data defining a geometry for a three-dimensional object to be fabricated;   a fabrication mechanism to form a portion of the object by addition of a material, substantially consistent with the digital data for a corresponding portion of the geometry;   wherein the material supply cartridge comprises a unitary piece of material which occupies at least 70% of the volume of the cartridge.   
     
     
         2 . The apparatus of  claim 1  wherein the cartridge comprises a package which is consumed as the material is used for fabrication. 
     
     
         3 . The apparatus of  claim 2  wherein the package comprises a hydrophobic coating on the unitary piece of material. 
     
     
         4 . The apparatus of  claim 1  wherein the cartridge defines features including at least one of gear teeth, helical screw surfaces, a flange and an index step that form part of a drive that advances the material. 
     
     
         5 . The apparatus of  claim 1  wherein the cartridge comprises a molded shell of the material which is subsequently filled with the material. 
     
     
         6 . The apparatus of  claim 1  wherein a remnant of the material in a partially consumed cartridge may be used in conjunction with a new cartridge to more fully utilize material.