Patent ID: 7704424

Claim:
A method of making a seamless model comprising the steps of: a) providing at least one tank filled with a resin component and tank filled with a hardener component; b) delivering the resin component and hardener component from the tanks to a mix block and mixing the resin component and hardener component to produce a modeling paste wherein the modeling paste is a low density thixotropic curable paste comprising a resin composition and microballoons; c) dispensing the modeling paste onto an outer surface of a support in a continuous layer; d) curing the paste at room temperature; and e) machining the cured paste to a desired or pre-determined contour to form the seamless model wherein the microballoons are present in an amount of greater than about 50% and less than about 80% of the uncured paste by volume and wherein the density of the uncured paste is in the range of about 0.4 to about 0.9 g/cm 3 and wherein the resin composition comprises: (i) an epoxy resin; (ii) a thixotropic agent; and (iii) a hardener comprising at least one polyethyleneimine and at least one other amine having at least two hydrogen groups.