Patent ID: 8323429

Claim:
A method for producing a three-dimensional plaster object having a desired shape, the method comprising: (a) depositing a first layer of a calcium sulfate hemihydrate slurry that does not contain activating agents onto a support substrate in a predetermined pattern using a spray head, (b) activating the first layer of the calcium sulfate hemihydrate slurry by depositing at least one first activating agent on top of said first layer, (c) depositing a second layer of the calcium sulfate hemihydrate slurry on top of the first layer of the calcium sulfate hemihydrate slurry that was activated in step (b), (d) depositing at least one second activating agent on top of said second layer, wherein the first and second activating agents can be the same or different, (e) repeating steps (c) and (d) to form additional layers until the three-dimensional plaster object is formed, and (f) removing the three-dimensional plaster object from the support substrate, wherein the activating agents are present in amounts sufficient to accelerate the setting reaction of calcium sulfate hemihydrate and water to form set calcium dihydrate; wherein the layers of calcium sulfate hemihydrate slurry are deposited in thicknesses of about 0.01 mm to about 1.0 mm; and wherein no machining is required to form the plaster object into the desired shape.