The Sanders RTM pattern building process uses two moveable print heads-one deposits thermoplastic build material and the other deposits support wax. The deposited materials are dispensed from the print heads as hot liquid that solidifies upon impact with the cooler model layer. Selective droplet deposition permits line traces to be placed adjacent to each other to produce a uniform layer of materials. The print heads digitally deposit build and support materials to construct fine-featured patterns. The micro-droplet size defines the fine detail of the outer and inner perimeter surfaces. The RTM system uses non-toxic materials and processes and requires no special venting for normal operation. To ensure uniform layer thickness, the RTM has a milling tool that planes each of the inter-layers from 0.5 to 5 thousandths inch (12 to 125 microns) thickness that provides a smooth and level surface for successive build layers. An automatic vacuum system collects residue from each milling operation. The build table elevator is digitally controlled to within 0.000125 inches (3 microns). This variable slice thickness control feature enables models to be constructed with ultrasmooth surfaces, especially rounded contours, without stair stepping effects.

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