Certain examples described herein relate to manufacturing a three-dimensional object. In some cases, a layer of build material is formed. An array of heat sources is controlled to selectively heat a sub-region of the layer of build material. Each heat source is individually addressable in the array to emit radiation independently of any other heat source in the array. Each heat source comprises a light-emitting diode, LED. In some cases, a fusing agent is deposited onto at least a part of the heated sub-region. Energy is applied at least to the deposited fusing agent to enable fusing of build material to fabricate a layer of the three dimensional object.

A method of forming an implant includes providing a preformed shell formed from at least one cured elastomeric layer. The preformed shell includes an outer surface, an inner surface, and an opening for accessing an interior volume of the preformed shell. The method further includes expanding the preformed shell to an expanded state, in which the interior volume is greater than the interior volume of the preformed shell at a time of forming the preformed shell and forming an inner zone having at least one inner elastomeric layer on at least a portion of the inner surface of the preformed shell, while the shell is in the expanded state, thereby forming a multi-zone shell. The method further includes reducing the interior volume of the multi-zone shell, thereby contracting the at least one inner elastomeric layer of the inner zone and causing texturing of the at least one inner elastomeric layer.

Provided herein is a polymerizable liquid composition useful for additive manufacturing, which composition may include: (i) a free radical photoinitiator; (ii) monomers and/or prepolymers (e.g., reactive diluents) that are polymerizable by exposure to actinic radiation or light, optionally wherein some or all of said monomers and/or prepolymers comprise one or more acid-labile or base-labile groups; (iii) a crosslinker comprising one or more acid-labile or base-labile groups; and (iv) a photoacid generator or a photobase generator, wherein said free radical photoinitiator and said photoacid generator or photobase generator are, or are selected to be, activated by light at different ranges of wavelengths or intensities. Methods of forming a three-dimensional object with the composition, and articles so formed are also provided. Methods of removing a portion of the article by dissolving in a polar or non-polar solvent are further provided.

The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.

Methods of producing an additive manufactured part with a smooth surface finish include providing a spinning device that has a platform. The part is secured to the platform, where the part is at least partially wetted with uncured resin from a resin pool. The platform is rotated, where a first portion of the uncured resin is retained on the part and a second portion of the uncured resin is removed. The part is cured after the rotating. In some embodiments, methods include creating a compensated design for a part by modifying a desired design to compensate for a first portion of an uncured surface finish material to be retained on the part, and forming the part with an additive manufacturing process according to the compensated design.

A structure forming method of present invention includes a first step including forming a first pattern serving as a fine pattern using an electromagnetic wave thermal conversion material on a first surface, on the side on which an expansion layer which expands by heating is provided, of a medium including the expansion layer and then irradiating an electromagnetic wave toward the electromagnetic wave thermal conversion material to expand a portion, corresponding to the first pattern, of the expansion layer, and a second step including forming a second pattern including a coarser pattern than the first pattern using an electromagnetic wave thermal conversion material on a second surface, on the opposite side to the side on which the expansion layer is provided, of the medium and then irradiating an electromagnetic wave toward the electromagnetic wave thermal conversion material to expand a portion, corresponding to the second pattern, of the expansion layer.

A method of manufacturing a sandwich structure having an open cellular core and a fluid-tight seal surrounding the core includes coupling a mold to a first facesheet to define a reservoir. The method also includes irradiating a volume of photo-monomer in the reservoir with a series of vertical collimated light beams to form a cured, solid polymer border extending around a periphery of the first facesheet. The method also includes irradiating a remaining volume of photo-monomer in the reservoir with a series of collimated light beams to form an ordered three-dimensional polymer microstructure core defined by a plurality of interconnected polymer optical waveguides coupled to the first facesheet and surrounded by the cured, solid polymer border. The method further includes coupling a second facesheet to the ordered three-dimensional microstructure core and the cured, solid polymer border to form the sandwich structure.

An thermally expandable sheet includes a base and a thermal expansion layer arranged on one surface of the base and configured to be used in manufacture of a shaped object by swelling of at least a portion of the thermal expansion layer. The thermal expansion layer includes a first thermally expandable material having a first expansion initiation temperature and a first maximum expansion temperature, and a second thermally expandable material having a second expansion initiation temperature and a second maximum expansion temperature. The first expansion initiation temperature and the second expansion initiation temperature are high in comparison to a temperature of an environment in which the shaped object is to be placed. The second maximum expansion temperature is high in comparison to the first maximum expansion temperature.

A molding sheet includes a base and a thermal expansion layer laminated onto a first main surface of the base. The thermal expansion layer includes a first thermal expansion material and a second thermal expansion material. A maximum expansion temperature of the second thermal expansion material is higher than a maximum expansion temperature of the first thermal expansion material.

An expansion apparatus includes: a first expander for irradiating with electromagnetic waves emitted from a lamp a thermal conversion layer for conversion of the electromagnetic waves to heat, to cause at least a portion of a thermal expansion layer to expand, the thermal conversion layer being laminated to a molding sheet including a base and the thermal expansion layer laminated to a first main surface of the base; and a second expander for causing expansion of a region (C) of the thermal expansion layer that is smaller in size than a region (B) of the thermal expansion layer expanded by the first expander.