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A novel process named ‘individual layer fabrication (ILF)’ is presented, in which objects are built up by laminating individually contoured wood-based panels. However, contrary to the well-known process of ‘laminated object manufacturing (LOM)’, in ILF, the individual panels are not shaped by a subtractive process but additively by selective binding of wooden particles. The particles are spread as a thin layer onto a built platform. A liquid adhesive is then applied only to those areas where the contoured panel is to be generated. As each layer is fabricated individually, the ILF process allows the application of mechanical pressure. Thereby, compared to other additive manufacturing techniques, the necessary amount of binder can be significantly reduced and mechanical properties comparable to particle boards can be achieved.

Individual layer fabrication (ILF): a novel approach to additive manufacturing by the use of wood