US Patent 7542205 Multi-object controlled-depth matrix layer structure and manufacturing process

A controlled-depth matrix layer structure is formed by floating a plurality of geometric shapes in a solidifiable liquid, then solidifying the liquid to entrap the plurality of geometric shapes in a layer. Multiple layers of liquid may be used, one or more of which may be solidifiable, so long as the sum of displaced masses of all the layers is greater than the mass of the geometric shapes, thereby causing the geometric shapes to float. The resulting structure after solidification of the solidifiable layer is a solidified layer interconnecting the plurality of geometric shapes, wherein each of the plurality of geometric shapes is within the solidified layer a specified percentage. The geometric shapes are preferably of different sizes, and may be spheres, hemispheres, or other suitable shapes, and may be hollow, solid, transparent or reflective.