Patent Document ID: 9114571
Application ID: 13661287
Patent Flag: 1

Claim One:
1. A method of fabricating a three-dimensional model which minimizes occurrence of any stress flaw within the three-dimensional model in which the three-dimensional model is formed from a sacrificial material and a model material, and the method comprising the steps of: selecting a desired model material; selecting a desired sacrificial material having a first density; selecting at least one additive having a second density, the second density of the at least one additive being ±10% of the first density of the sacrificial material; adding the at least one additive to the sacrificial material for at least one of: increasing a thermal conductivity of the sacrificial material, decreasing a coefficient of thermal expansion of the sacrificial material and decreasing an ability of the sacrificial material to transmit stress to the model material; forming a uniform composite sacrificial material by dispersing the at least one additive within the sacrificial material uniformly, and suspending the at least one additive within the sacrificial material and minimizing a likelihood that the at least one additive will separate and settle from the sacrificial material; building a three-dimensional composite model by depositing a plurality of layers, one on top of another, with each layer comprising selective deposition of at least one of the composite sacrificial material and the model material; and following completion of the three-dimensional composite model, separating the composite sacrificial material from the model material by a dewaxing process, and during the dewaxing process, using at least one of the increase in the thermal conductivity of the sacrificial material, the decrease in the coefficient of thermal expansion of the sacrificial material and the decrease the ability of the sacrificial material to transmit stress to the model material to remove the composite sacrificial material from the model material without creating any stress flaws in the three-dimensional model.