Patent ID: 6841116

Claim:
A method of forming a three-dimensional object in a layerwise manner, the method comprising the steps of: generating computer data corresponding to layers of the object; providing a thermally stable dispensing environment for a radiation curable phase change material having at least one reactive component, the dispensing environment having a dispensing temperature wherein the material can be maintained at the dispensing temperature in a flowable state for a desired time period while the reactive component of the material remains substantially uncured; dispensing the radiation curable phase change material in a flowable state at the dispensing temperature according to the computer data to form layers of the object; dispensing a non-curable phase change material to form supports for the object; lowering the temperature of the dispensed material causing the radiation curable phase change material to solidify to a non-flowable state; supporting a first dispensed layer of the three-dimensional object and providing a working surface for forming subsequent layers on top of a previous layer; curing the solidified material by exposure to radiation; and removing the non-curable phase change material forming the supports from the object.