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A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) operating a material deposition sub-system for dispensing droplets of solidifiable liquid compositions on demand onto selected spots of an object work surface, for using a

A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) operating a material deposition sub-system for dispensing droplets of solidifiable liquid compositions on demand onto selected spots of an object work surface, for using a focused heat source to maintain a heat-affected zone on the work surface, and for creating a weld pool of molten materials on this work surface by injecting selected powder particles into this heat-affected zone and (2) during the material deposition process, moving the deposition sub-system and the work surface relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the object. The material in the weld pool solidifies after the heat-affected zone moves away to build portions of a layer. These steps are repeated to deposit multiple layers for forming a three-dimensional shape. Preferably, the peripheral areas and the staircase step zones between layers are built with fine droplets for improved part accuracy while the bulk of the object is built with solidification of weld pool materials. These steps are preferably executed under the control of a computer system. Preferably, the system is also operated to generate a support structure for any un-supported feature of the object.

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1. Solid freeform fabrication apparatus for making a three-dimensional object, comprising:(a) a work surface; (b) a material deposition sub-system, disposed above and in working proximity to said work surface, comprising: a liquid droplet deposition device comprising (1) a multiplicity of flow chann

1. Solid freeform fabrication apparatus for making a three-dimensional object, comprising:(a) a work surface; (b) a material deposition sub-system, disposed above and in working proximity to said work surface, comprising: a liquid droplet deposition device comprising (1) a multiplicity of flow channels with each channel being supplied with a solidifiable liquid composition, (2) at least one nozzle having, on one end, a fluid passage in flow communication with one of said multiple channels and, on another end, a discharge orifice of a predetermined size, and (3) actuator means located in control relation to said channels for activating ejection of droplets through said discharge orifice; a focused heat source disposed in working proximity to said work surface and operative to produce a heat-affected zone on said work surface; a powder-dispensing device, disposed in close proximity to said liquid droplet deposition device, comprising (1) at least a flow channel being supplied with solid powder particles, (2) at least one nozzle having, on one end, a flow passage in flow communication with said flow channel and, on another end, a discharge orifice of a predetermined size, and (3) valve means located in control relation with said flow channel and operative to inject solid powder particles to said heat-affected zone for forming a weld pool of molten material; (c) motion devices coupled to said work surface and said material deposition sub-system for moving said deposition sub-system and said work surface relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said liquid droplets and weld pool material, collectively referred to as deposition materials, into a three-dimensional shape.