Rapid Pro to Typing Case Study

8/11/2019 Rapid Pro to Typing Case Study

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RAPID PROTOTYPING

IME 545 CASE STUDY


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CONTENTS

What is Rapid Prototyping (RP)?

Why Would You Use RP?

Growth of RP in Last 10 Years

Types of RP Machines Available System Designs

Materials Used

Examples How much do they cost?

Obstacles Yet to Overcome for RP

References


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Rapid Prototyping (RP) Defined

What is rapid prototyping?

It is a process that creates parts in an additive, layer-by-layer manner.

A special class of machine technology that quickly produces models and prototype parts

from 3-D data using an additive approach to form the physical models.

Rapid prototyping (RP) is a relatively new class of technology used for building physical

models and prototype parts from 3D CAD data. Unlike CNC machines tools, which are

subtractive in nature, RP systems join together liquid, powder and sheet materials to form

complex parts. Layer by layer, RP machines fabricate plastic, wood, ceramic, and metal

objects based on thin horizontal cross sections taken from a computer model.


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WHY USE RP?

The obvious benefit of rapid prototyping is speed.

Rapid prototyping quickly delivers a better design communication tool, the physical prototype

quickly and clearly communicates all aspects of a design.

Rapid prototyping facilitates the early detection and correction of design flaws.

In its simplest form, the benefit of rapid prototyping is confidence in the integrity of the design.


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Growth of RP in Last 10 Years

10 Years ago

Eleven companies manufactured and sold RP machines. Four were from the U.S., four from Japan, and one eachfrom Germany and Israel.

RP system manufacturers in total sold 157 machines worldwide. Sales of RP products and services were anestimated $99.3 million.

Worldwide, about 80 companies operated as RP service providers.

Thirty-eight universities, government laboratories and corporations around the globe had researched or developedsome aspect of RP technology.

Today

Last year, 28 companies manufactured and sold RP machines. Eleven were from the U.S.; seven from Japan; fourfrom Germany; three from China; and one each from Singapore, Sweden, and Israel.

In 2003, sales are expected to exceed 1,400 units. Sales for 2003 were forecast at $590 million.

At the end of 2001, an estimated 397 service providers were in place.

Through the end of last year, a conservative estimate of more than 500 organizations worldwide had developedsome facet of RP equipment, software, or materials technology.

A $1,000 prototype in 1993 now sells for as little as $150 to $250.


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STEREOLITHOGRAPHY (SLA)

Stereolithography is the most widely used

rapid prototyping technology.

Stereolithography builds plastic parts a layer at

a time by tracing a laser beam on the surface ofa vat of liquid photopolymer. The

photopolymer material quickly solidifies

wherever the laser beam strikes the surface of

the liquid.

Once one layer is completely traced, it's

lowered a small distance into the vat and a

second layer is traced right on top of the first. The self-adhesive property of the material

causes the layers to bond to one another and

eventually form a complete, three-dimensional

object after many such layers are formed.


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Some objects have overhangs or undercutswhich must be supported during the fabricationprocess by support structures.

Supports are either manually or automaticallydesigned and fabricated right along with theobject. Upon completion of the fabricationprocess, the object is elevated from the vat andthe supports are cut off.

Stereolithography generally is considered toprovide the greatest accuracy and best surfacefinish of any rapid prototyping technology.

Over the years, a wide range of materials withproperties mimicking those of severalengineering thermoplastics have beendeveloped. Ceramic materials are currentlybeing developed.

The technology is also notable for the largeobject sizes that are possible.


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On the negative side, working with liquid

materials can be messy.

Parts often require a post-curing

operation in a separate oven-like

apparatus for complete cure and stability.

Supports must be removed from part.

Manufacturers of SLA Equipment

3D Systems

Light SculptingSony Precision Technology America

Teijin Seiki , JapanD-MEC, JapanDenken EngineeringUnirapid, Japan

Meiko, Japan

Autostrade Limited, Japan

Objet Geometries, Israel Envision Technologies GmbH, Germany

microTEC, Germany

F&S Stereolithographietechnik GmbH,Germany


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SLA Materials

Photopolymers are imaging compositions

based on polymers/oligomers/monomers

which can be selectively polymerizedand/or crosslinked upon imagewise

exposure by light radiation such as ultra-

violet light.


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FUSED DEPOSITION MODELING (FDM)

FDM is the second most widely used rapidprototyping technology, afterstereolithography.

A plastic filament is unwound from a coil andsupplies material to an extrusion nozzle. Thenozzle is heated to melt the plastic and has amechanism which allows the flow of themelted plastic to be turned on and off. Thenozzle is mounted to a mechanical stage whichcan be moved in both horizontal and verticaldirections.

As the nozzle is moved over the table in therequired geometry, it deposits a thin bead ofextruded plastic to form each layer.

The plastic hardens immediately after beingsquirted from the nozzle and bonds to the layerbelow.

The entire system is contained within achamber which is held at a temperature justbelow the melting point of the plastic.


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Several materials are available for the processincluding ABS and investment casting wax.

ABS offers good strength, and more recentlypolycarbonate and polysulfone materials havebeen introduced which extend the capabilitiesof the method further in terms of strength andtemperature range.

Support structures are fabricated foroverhanging geometries and are later removedby breaking them away from the object. Awater-soluble support material which cansimply be washed away is also available.

The method is office-friendly and quiet. FDMis fairly fast for small parts on the order of afew cubic inches, or those that have tall, thinform-factors. It can be very slow for parts withwide cross sections, however. The finish ofparts produced with the method aren't quite ona par with stereolithography.


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Can be used in any office environment

without special venting or facility

requirements.

Material used typically is ABS

Automatic postprocessing is available

that allows you to dissolve temporary

support structures rather than manually

remove them.

Dr. Ryan Brown of ISU has this model.

Z CORP is a representative manufacturer

of FDM RP machines.


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FDM MATERIALS

Materials

ABS, Acrylonitrile-butadiene-styrene

ABS is a common end-usethermoplasticmaterial withconsiderable durability. Thismaterial is ideal for a variety ofmodeling and prototyping activitiesdue to its stiffness and ease offinishing.

ABS Materials Specifications:

Tensile Strength 5,000 psi Tensile Modulus 360,000 psi

Elongation 50.00%

Flexural Strength 9,500 psi

Rockwell Hardness R105

Vicat Softening Point 220 (v)

Specific Gravity 1.05 g/cc

Polysulfone

This tough, rigid, high-strength thermoplastic

has a heat deflection temperature of 343F

(174C), and maintains its properties over a

wide temperature range. Transparent, opaque

and glass-fiber reinforced grades are available.


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FDM MATERIALS

Polycarbonate

The material out of which CDs and

CD-ROMs are made.

A thermoplasticpolymer resin that

is linear polyester of carbonic acid.

Polycarbonate is a transparent,

nontoxic, non-corrosive, heat

resistant, high impact strength

plastic; it is generally stable, but

may be subject to attack by strongalkalis and some organic

hydrocarbons.


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INKJET (THERMAL PHASE CHANGE)

This machine uses a single jet each for a plasticbuild material and a wax-like support material,which are held in a melted liquid state inreservoirs.

The liquids are fed to individual jetting headswhich squirt tiny droplets of the materials asthey are moved in X-Y fashion in the requiredpattern to form a layer of the object. Thematerials harden by rapidly dropping intemperature as they are deposited.

After an entire layer of the object is formed byjetting, a milling head is passed over the layer

to make it a uniform thickness. Particles arevacuumed away as the milling head cuts andare captured in a filter.

The process is repeated to form the entireobject. After the object is completed, the waxsupport material is either melted or dissolvedaway.


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INKJET (THERMAL PHASE CHANGE)

The most outstanding characteristic of inkjet

systems is the ability to produce extremely fine

resolution and surface finishes, essentially

equivalent to CNC machines. The technique is very slow for large objects.

While the size of the machine and materials are

office-friendly, the use of a milling head

creates noise which may be objectionable in an

office environment.

All thermal phase changeinkjets have

material limitations and make fragile parts. The

applications range from concept models to

precise casting patterns for industry and the

arts, particularly jewelry.

3D Systems is a representative manufacturer of

Inkjet RP machines.


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INKJET

(PHOTOPOLYMER WIDE AREA HEAD)

The process is based on photopolymers,but uses a wide area inkjet head tolayerwisedeposit both build and support

materials. It subsequently completelycures each layer after it is deposited witha UV flood lamp mounted on the printhead.

The support material, which is also aphotopolymer, is removed by washing itaway in a secondary operation. The low

initial system price, approximately $65K,and specifications that are similar tolaser-based stereolithography systemscosting ten times as much make this animportant technology to watch.

Objet Geometries Ltd., is arepresentative manufacturer of wide area

inkjet RP machines.


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SELECTIVE LASER SINTERING (SLS)

Thermoplastic powder is spread by a rollerover the surface of a build cylinder. The pistonin the cylinder moves down one object layerthickness to accommodate the new layer of

powder. The powder delivery system is similar in

function to the build cylinder. Here, a pistonmoves upward incrementally to supply ameasured quantity of powder for each layer.

A laser beam is then traced over the surface ofthis tightly compacted powder to selectivelymelt and bond it to form a layer of the object.

The fabrication chamber is maintained at atemperature just below the melting point of thepowder so that heat from the laser need onlyelevate the temperature slightly to causesintering. This greatly speeds up the process.The process is repeated until the entire object isfabricated.


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SELECTIVE LASER SINTERING

Materials

A variety of thermoplastic materials such

as nylon, glass filled nylon, and

polystyrene are available. The methodhas also been extended to provide direct

fabrication of metal and ceramic objects

and tools.

Since the objects are sintered they are

porous. It may be necessary to infiltrate

the part, especially metals, with another

material to improve mechanicalcharacteristics.

Impellers for an aerospace application directly

fabricated by selective laser sintering (SLS).


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3Dimensional Printing

Three dimensional printing was developed atMIT. It's often used as a direct manufacturingprocess as well as for rapid prototyping.

The process starts by depositing a layer ofpowder object material at the top of afabrication chamber. To accomplish this, ameasured quantity of powder is first dispensedfrom a similar supply chamber by moving apiston upward incrementally. The roller thendistributes and compresses the powder at thetop of the fabrication chamber.

The multi-channel jetting head subsequently

deposits a liquid adhesive in a two dimensionalpattern onto the layer of the powder whichbecomes bonded in the areas where theadhesive is deposited, to form a layer of theobject.


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Once a layer is completed, the fabrication

piston moves down by the thickness of a layer,

and the process is repeated until the entire

object is formed within the powder bed. Aftercompletion, the object is elevated and the extra

powder brushed away leaving a "green" object.

No external supports are required during

fabrication since the powder bed supports

overhangs.

Three dimensional printing offers the

advantages of speedy fabrication and low

materials cost. In fact, it's probably the fastestof all RP methods. Recently color output has

also become available. However, there are

limitations on resolution, surface finish, part

fragility and available materials.


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3D printing is a less costly and less capablevariation of rapid prototyping (RP) technology.

Vendor companies are positioning them asmachines that can give you a quick andinexpensive model early in the design process.

Because of their relatively low cost, small size,and office friendliness, user companies areinstalling them in offices near their CADsystems.

The results of finite element analysis are beingapplied to RP using Z Corp.'s Z402C color 3-Dprinter. The effect is an easily interpreted FEAstress plot.

Example products are the Z402C from ZCorporation, Dimension from Stratasys,QuadraTempo from Objet Geometries, andThermoJet from 3D Systems.

Materials are plaster or starch based and can beinfiltrated with wax, polyurethane or epoxy.


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LAMINATED OBJECT MANUFACTURING (LOM)

The paper is unwound from a feed roll onto the

stack and first bonded to the previous layer

using a heated roller which melts a plastic

coating on the bottom side of the paper. The profiles are then traced by a laser optics

system that is mounted to an X-Y stage.

After cutting of the layer is complete, excess

paper is cut away to separate the layer from the

web. Waste paper is wound on a take-up roll.

The method is self-supporting for overhangs

and undercuts. Areas of cross sections which are to be

removed in the final object are heavily cross-

hatched with the laser to facilitate removal. It

can be time consuming to remove extra

material for some geometries, however.


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LAMINATED OBJECT MANUFACTURING (LOM)

In general, the finish, accuracy and stability ofpaper objects are not as good as for materialsused with other RP methods. However,material costs are very low, and objects have

the look and feel of wood and can be workedand finished in the same manner.

This has fostered applications such as patternsfor sand castings. While there are limitationson materials, work has been done with plastics,composites, ceramics and metals. Some ofthese materials are available on a limitedcommercial basis.

The principal commercial provider of LOMsystems, Helisys, ceased operation in 2000.However, there are several other companieswith either similar LOM technology, or in earlycommercial stages.

Cubic Technologies is a representativemanufacturer of LOM RP machines.

Terrain model of the earth fabricated by laminated

object manufacturing (LOM).


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LASER ENGINEERED NET SHAPING (LENS)

Laser Engineered Net Shaping (LENS)technologies are in early stages ofcommercialization.

A high power laser is used to melt metalpowder supplied coaxially to the focus of thelaser beam through a deposition head.

The laser beam typically travels through thecenter of the head and is focused to a smallspot by one or more lenses. The X-Y table ismoved to fabricate each layer of the object.

The head is moved up vertically as each layeris completed. Metal powders are delivered anddistributed around the circumference of thehead either by gravity, or by using apressurized carrier gas.

An inert shroud gas is often used to shield themelt pool from atmospheric oxygen for bettercontrol of properties, and to promote layer tolayer adhesion by providing better surfacewetting.


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LASER ENGINEERED NET SHAPING

A variety of materials can be used such asstainless steel, Inconel, copper, aluminum andtitanium.

The strength of the technology lies in the

ability to fabricate fully-dense metal parts withgood metallurgical properties at reasonablespeeds.

Objects fabricated are near net shape, butgenerally will require finish machining.

They have good grain structure, and haveproperties similar to, or even better than theintrinsic materials.

Selective laser sintering (SLS) is at present theonly other commercialized RP process that canproduce metal parts directly.

LENS forming methods have fewer materiallimitations than SLS, don't require secondaryfiring operations as some of those processesdo, and can also be used to repair parts as wellas fabricate them.

Titanium Engine Valves


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COST OF RP SYSTEMSStereo- Wide Area Single Jet Three

lithography Inkjet Inkjet Dimensional

Printing

Cubic

Technologies

Maximum Part

Size (inches) 20 x 20 x 24 10 x 8 x 8 15 x 13 x 18 24 x 20 x 24 12 x 6 x 9 20 x 24 x 16 32 x 22 x 20Speed average good average to fair poor poor excellent good

Accuracy very good good good fair excellent fair fair

fair to poor

(depending onapplication)

marke t le ade r, mark et le ader, ma rket lea de r, office okay, accuracy, speed, large part size,

large part size, office okay, accuracy, price, finish, office okay, good for largecastings,

accuracy, materials, materials, office okay, price, material cost

wide product line color,

price

size and weight, size and weight, speed, limited materials, part stability,

fragile parts, system price, limited materials, fragile parts, smoke

limited materials, surface finish part size finish finish and accuracy

part size

System Price $75-800K $50K $300K $30-300K $70K-80K $30K-70K $120-240K

plastics $75-110 $100 $30-60 $115-185 $100 $9

metal $25-30

$5 starch:

(foundry sand) $0.35 / cu inplaster:

$0.60 / cu in+ infiltrant

3D Systems Stratasys Solidscape

Technology >>

Selective Laser

Sintering

Fused Deposition

Modeling

Laminated Object

Manufacturing

Z Corp.

General Qualitative Features

Surface Finish very good fair fair fair excellent fair

Representative

Vendor >>

Strengths

Weaknesses

post processing,messy liquids

speed

Material Costs $/pound

other $5-8 (paper)


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TURNAROUND TIMES

Technology - >> Inkjet FDM 3DP SLS LOM SLA

Material

wax-like

plastic ABS plaster polystyrene paper

epoxy-based

photopolymer

Accuracy vs CAD

(inches) 0.013 0.014 0.025 0.018 0.01 0.006

Build Time 7 hr 17 min 42 hr 10 min 5 hr 40 min 6 hr 51 min 19 hr 39 min 26 hr 19 min

Cost $146.00 $421.60 $113.20 $268.00 $393.20 $789.90

Comparison of Rapid Prototyping Technologies


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EXAMPLES

DentistryCynovad (Montreal, Canada) announced an agreementto purchase several hundred ThermoJet printers from3D Systems (Valencia, CA), which are to be re-

branded as WaxPro. Cynovad is the exclusive reseller

of these machines to the more than 50,000 dental labsaround the world for the production of crowns, bridgesand other types of dental restorations. The machines

produce wax patterns needed for the investmentcasting process.

Formula 1 RacecarsIn England, a service provider named 3T RPD(Berkshire, UK) is using RP to supply parts for theJordan-Honda Formula 1 racecars. Some of the 20

different parts are used as prototypes, but many areproduced as final production parts for cars built to winraces. These parts include replacement panels thatform aerodynamic skins, cooling ducts and electrical

boxes. According to 3T RPD president Tim Plunkett,the company is supplying Jordan-Honda with anaverage of 35 laser sintered parts per week with atypical deliver of only 48 hours.


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EXAMPLES

Custom Fil tersUsing 3-D printing (3DP) technology from theMassachusetts Institute of Technology (MIT), SpecificSurface (Franklin, MA) is manufacturing highlycomplex ceramic filters that are applied to everything

from making soy sauce to filtering diesel emissions.Using its CeraPrint process, Specific Surface producesfilters in quantities of 10 to 100,000.

Toxi cology StudiesDoug Greenwood of Product Development Service(Durham, NC) has used DSM Somos' (New Castle,DE) WaterClear material to model a human nasal

passage for CIIT Centers for Health Research. The

transparency of the cured photopolymer permitsvisualization of air and particulate flow for improvedunderstanding of chemical interaction with the nasalmembrane. Both companies believe that thecomplexity of this internal passage makes it nearlyimpossible to physically model using any method otherthan RP.


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EXAMPLES

Mini ature Parts

RP processes are producing very small parts, some as tiny as a red blood cell. The University of Southern California is

using a process it calls electrochemical fabrication that electro-deposits nickel layer-by-layer using a masking technique.

With this method, it is possible to produce working mechanisms that measure 100 microns (0.004 inch) in height.

Worl d's Smallest RobotUsing stereolithography, Sandia National Laboratories (Albuquerque, NM) has built what it believes is the world's

smallest untethered robot. The mobile unit weighs less than one ounce and measures 0.25 cubic inch.

Hearing Aids

Many of the major manufacturers of hearing aids are in the early stages of using RP to mass customize their products in

impressive volumes. Some of these companies produce more than 1,000 in-the-ear hearing aids per day, each being

unique in its shape and size. A silicone rubber impression of the ear canal is digitized with an optical scanner, which leads

to an STL file and RP for the rapid production of the hearing aid shell.

Burn M asksRP is being using to produce custom-fit masks that reduce scarring on burn victims. The process begins by digitizing the

patient using non-contact optical scanning. The scan data is used to produce an RP model of a mask that fits perfectly to

the patient's face.


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EXAMPLES

RP for the Production of F in ished Manufactured PartsAn increasing number of companies have demonstrated RP's ability to produce finished goods. Theseprogressive companies have laid the groundwork for others to follow. Additional examples include:Technikon Free State (Bloemfontein, South Africa) using laser sintering to manufacture a monitoring

device for fitness centers; and a user of Stratasys' (Eden Prairie, MN) FDM Titan producing apolycarbonate replacement pulley for an industrial belt sander.

Growing Demand in the Medical I ndustryMany medical applications demand some level of personal customization, and RP has demonstrated theability to address this need. Andy Christensen of Medical Modeling LLC (Golden, CO) says the demandfor RP models in the medical industry has doubled during the past two to three years. Align Technology(Santa Clara, CA) has developed more than one million RP models, using its stereolithography machinesto produce its Invisalign invisible plastic aligners for straightening adult teeth. Separately, Interpore

Cross International (Irvine, CA), a medical device company, is using seven ModelMaker machines fromSolidscape (Merrimack, NH) to manufacture spinal implants.

Micro PartsWith computers and hand-held electronic devices shrinking, the appetite for small parts grows. RP'sstyle of building parts in layers, coupled with lasers, makes it possible to produce very small parts andassemblies that are highly complex. The number of activities in this area suggests that a trend isdeveloping for the production of miniature parts through RP for wide ranging applications and productssuch as actuators and sensors.


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Obstacles Yet to Overcome for RP

Produce a truly push-button system.

Build metal parts and tools directly. We have

experienced some impressive progress

throughout the past few years, but many wouldargue that the development of machines that

produce metal parts leaves room for

improvement.

Accept smooth surface data from the CAD

systems. RP systems still do not accept

mathematically smooth surface data.

Fortunately, the cost and performance of

desktop computers have improved so much

that it is no longer a problem to reduce the

triangular facet size in STL models to the point

at which the surfaces appear smooth.

RP vendors must become fiscally sound.

Today, most companies in the business of

manufacturing RP systems continue to

struggle.

Improve the price/performance ratio. Vendors

continue to introduce new machines that give

customers a bigger bang for the buck. Many

customer prospects have voiced their views on

the idea of a low-cost machine. To some, low

cost means $20,000. To others, it means

$2,000. We have yet to reach either milestone,

although we are closing in on the first one.


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FUTURE OF RP

In analyzing the computer industry, Bill Gates once said that people tend to over estimatewhat will happen in three years and underestimate what will occur in six.

10 Predictions for the Future of RP

1. The " chasm" is crossed. The gap in the technology lifecycle adoption curve is createdby the difference in decision-making style between risk-taking early adopters and themajority. Until the chasm is bridged, technology cannot gain the momentum that propels itinto wide use.

2. A 24 percent decline in system manufacturers.Survival for today's 28 RP machinemanufacturers is not guaranteed. Several are on life support and are unlikely to sustainexistence in their present form. Nine of the current vendors will fail or be acquired byanother organization.

3. A F ortune 500 company explodes onto the stage. The RP industry will become tooattractive for major players to ignore. 3D Systems may have enabled this development bypaving the way for Canon. On June 14, 2000, 3D Systems announced that Canon SalesCompany would market ThermoJet systems in Japan. Canon may be using this distributionstrategy to survey the RP landscape to plan its entry into the world of 3-D printing.Whether it's Canon, Hewlett-Packard or Fuji-Xerox, an established company willmanufacture, distribute and support a 3-D printer.


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FUTURE OF RP

4. A common tool in education.A significant plunge in the price of an RP machine will

make it possible for even the most budget-strapped schools to claim ownership. With

special educational offers, hundreds of public and private schools throughout the U.S. will

purchase an inexpensive, but impressively functional, 3-D printer. 5. I ntolerance for the three H 's.Hazards, hassles and headaches will not be tolerated.

6. The I nternet takes hold of RP transactions.Overburdened project engineers will not

have the luxury of spending days to secure quotes, outsource prototypes and manage the

supply chain. Using the wide-reaching power of the Internet, corporations will gain

confidence that they are receiving the best value for their money.

7. I n li ving color.The preference for color is obvious; color photography, color charts andgraphs, color monitors and color CAD models. Color enhances the communication

potential for RP. The results of finite element analysis are being applied to RP using Z

Corp.'s Z402C color 3-D printer. The effect is an easily interpreted FEA stress plot.


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FUTURE OF RP

8. Digital supercedes physical. Already, digital models (e.g., CAD solid modeling) have reduced theneed for physical models and prototype parts. Today, companies routinely produce multiple versions ofa new design, digitally, before it is fabricated. As CAD and computer simulation tools improve, and asproduct development teams are forced to further reduce time-to-market, the number of prototypes will

shrink.

9. Unthinkable applications emerge. The vast array of potential applications is exciting. Organizationswill rely on methods of RP for sculpture, architecture, mold flow analysis, molecular modeling and awide array of other interesting and unusual uses. Breakthrough applications have already emerged. RPhas been used in forensics to solve murder mysteries; it is a critical component in creating "invisible"braces for orthodontics; and it has helped those in dire medical situations.

10. RP translates to Rapid Producti on. Perhaps solid freeform fabrication is a better term to describethe class of technology that we today refer to as RP. Indeed, rapid prototyping is the single largestapplication of this technology, but it can extend well beyond prototyping. In six years, companies willroutinely use methods of RP for the production of manufactured parts. Investigations are already underway for the appropriate use of RP to manufacture relatively small parts in volumes of hundreds and eventhousands. Mass customization - should it ever be realized - will most likely rely on some form of thetechnology that we know today as rapid prototyping.


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Rapid Prototyping & Tooling Service Providers

Accelerated Technologies, Inc. (ATI) Visual models, functional prototypes, and tooling capabilities; 16SLS and SLA machines.

AeroMetLaser additive manufacturing of titanium alloy structures. AerosportCNC milling, stereolithography, RTV molding, vacuum forming, fiberglass and composites,

custom finishing, 3D modeling, industrial design, and mechanical engineering.

Aristo CastProducer of investment castings, including low volume prototypes and high volumeproduction quantities.

ArptechUses Genisys Xs to produce physical models from CAD data; located in Australia.

ARRK Product DevelopmentRapid prototyping, CAD/CAM, CNC, machining, fabricated prototypes,vacupressure molding, and complete product finishing.

Applied Rapid Technologies Corp3D design services, stereolithography, vacuum cast urethane parts,

and rapid "bridge" tooling for injection molded plastics.Automated 3D ModelingRapid production of accurate models from CAD systems suitable for prototypesand rapid tooling; owns and operates Rapid ToolMaker from Sanders Design International.

BastechCAD, engineering, SLA, SLS, plastic and metal reproductions, prototype tooling, and short-runinjection molding.

BertrandtGerman company with a wide range of services for the complete development of anautomobile.
http://www.atirapid.com/http://www.aerometcorp.com/http://www.aerosportmodeling.com/http://www.aristo-cast.com/http://www.arptech.com.au/http://www.arrk.com/http://www.artcorp.com/http://www.a3dm.com/http://www.bastech.com/http://www.bertrandt.com/http://www.bertrandt.com/http://www.bastech.com/http://www.a3dm.com/http://www.artcorp.com/http://www.arrk.com/http://www.arptech.com.au/http://www.aristo-cast.com/http://www.aerosportmodeling.com/http://www.aerometcorp.com/http://www.atirapid.com/


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CAM-LEMUses a special lamination process to manufacture components, prototype molds, and toolingin metal or ceramic directly from a 3D CAD file.

C.ideasFDM services.

Clinkenbeard & AssociatesRapid prototyping, tooling, CNC, castings.

Conceptual RealitySLA, FDM, SLS, composite, kirksite, silicone rubber, zinc/aluminum plaster casting,spray metal, sand casting, injection molding, cast urethane, and investment casting.

Design Prototyping TechnologiesSLA, SLS, urethane and rapid metal castings, composite tooling.

Eagle Design & TechnologyAssist industry in the design/build process from, prototype to production.

Ekco PlasticsSLA, FDM, LOM, design services, rapid tooling, mold design, moldmaking, plasticsmolding, and seminars.

Engineering & Manufacturing Services(EMS) 3D printed parts from Z Corp's color machine.

Experimental FactoryResearch, testing, demonstration, and service center in Magdeburg, Germany.

Express PatternStereolithography parts, foundry patterns, and QuickCast investment casting patternsfor a variety of foundries and manufacturers.

FineLine PrototypingHigh-resolution small-spot stereolithography for the medical device and electricalconnector industries.

Fusion EngineeringRapid tooling and 3D prototyping for the plastic injection molding and die castingindustries.

Harvest TechnologiesConcept and functional models, investment and sand casting patterns, andpatterns for soft tooling; SLS, CNC.
http://www.camlem.com/http://www.prototype3d.com/http://www.clinkenbeard.com/http://www.conceptual-reality.com/http://www.dpt-fast.com/http://www.eagledesign.com/http://www.therapidsolution.com/http://www.ems-usa.com/http://www.exfa.de/en/http://www.expresspattern.com/http://www.finelineprototyping.com/http://www.fusionrpt.com/http://www.vvm.com/~harvesthttp://www.vvm.com/~harvesthttp://www.fusionrpt.com/http://www.finelineprototyping.com/http://www.expresspattern.com/http://www.exfa.de/en/http://www.ems-usa.com/http://www.therapidsolution.com/http://www.eagledesign.com/http://www.dpt-fast.com/http://www.conceptual-reality.com/http://www.clinkenbeard.com/http://www.prototype3d.com/http://www.camlem.com/http://www.camlem.com/http://www.camlem.com/


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Hoerdler Rapid EngineeringGerman company offering laser sintering, stereolithography, aluminum-filledepoxy tooling, vacuum casting, and CNC machining.

INCSA leading CAD and RP service and sales company in Japan.

JavelinArchitectural models, medical and anatomical prototypes, high-end CAD verification, sculpted art

pieces, and invention concepts. Laser InnovationsThird-party service and support of Coherent Ion laser systems and solid state laser

system integration.

Laser ReproductionsRapid product development; SLA.

M2 SystemsCustom jewelry and product development services using CAD, an RP machine fromSolidscape and CNC machining.

Metalcast EngineeringPlastic injection molding, stereolithography, machined models, and metal castingprototypes.

Morris TechnologiesPrototyping, metal casting, and low volume manufacturing; SLA, LOM.

National RP SupportHardware and software support on all models of the SLA and peripherals. Paramount IndustriesIndustrial design and mechanical and manufacturing engineering, complimented by

product development and manufacturing services.

PERIDOTEngineering service bureau that provides product and tool design and development.

PMLVirtual prototyping, tooling, digitizing, reverse engineering, and inspection; LOM, FDM, CNC.

ProtoCastCreate aluminum, zinc, and magnesium prototype castings without the expense of hard tooling

Protosys Technologies Private LimitedCAD/CAM, RP, RTV silicone rubber tooling, and epoxy tooling inIndia.
http://www.hoerdler.de/http://www.incs.co.jp/http://www.javelin3d.com/http://www.solidimaging.com/http://www.laserrepro.com/http://www.m2-systems.com/http://www.metalcast.com/http://www.morristech.com/http://www.rpsupport.com/http://www.paramountind.com/http://www.peridotinc.com/http://www.pmli.com/http://www.protcast.com/http://www.protosystech.com/http://www.protosystech.com/http://www.protcast.com/http://www.pmli.com/http://www.peridotinc.com/http://www.paramountind.com/http://www.rpsupport.com/http://www.morristech.com/http://www.metalcast.com/http://www.m2-systems.com/http://www.laserrepro.com/http://www.solidimaging.com/http://www.javelin3d.com/http://www.incs.co.jp/http://www.hoerdler.de/


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Prototech EngineeringSilicone rubber molding, spray metal tooling, and prototype metal castings; SLA,LOM.

Proto TechnologiesUrethane casting; SLA, CNC.

Quickparts.comInstant online quotes, RP, cast urethane parts, injection molded parts, die cast and sheet

metal parts, and CNC machined prototypes. Rapid Prototyping CenterFirst company in Finland to provide RP services.

Rapid SolutionsSilicone rubber tooling and epoxy tooling; SLA.

Rapid Tooling TechnologiesRapid tooling inserts using the 3D Keltool process.

3Dimensional EngineeringEngineering services, SLA, Actua, and rapid tooling.

3D-CAMDesign, SLA, SLS, RTV tooling, CNC machined tooling, aluminum epoxy tooling, Zap tooling,urethane casting, injection molding, QuickCast, and sand casting.

Shared ReplicatorsSLA and FDM (with ABS, polycarbonate, and polyphenylsulfone).

Solid ConceptsSilicone rubber tooling, TrueCast epoxy tooling, and aluminum tooling; SLA, CNC.

Soligen TechnologiesOffers a process called Direct Shell Production Casting (DSPC) for metal castings.

Specific SurfaceAdvanced computer controlled technology called CeraPrint based on MIT's 3D printing;manufactures advanced filters and substrates for industrial and diesel exhaust applications.

The Rapid SolutionDesign services, RP, RT, mold design, CAE, moldmaking, plastics molding, andseminars.

The Technology HouseProject management, product design and development, engineering, and rapidprototyping.

Xpress3DInstant on-line quoting for Z Corp. models and prototype parts.
http://www.prototechengineering.com/http://www.prototech.com/http://www.quickparts.com/http://www.rpc.fi/http://www.rapidsolutions.com/http://www.rapid-design.com/http://www.3de.net/http://www.3d-cam.com/http://www.sharedreplicators.com/http://www.solidconcepts.com/http://www.soligen.com/http://www.specsurf.com/http://www.therapidsolution.com/http://www.tth.com/http://www.xpress3d.com/http://www.xpress3d.com/http://www.tth.com/http://www.therapidsolution.com/http://www.specsurf.com/http://www.soligen.com/http://www.solidconcepts.com/http://www.sharedreplicators.com/http://www.3d-cam.com/http://www.3d-cam.com/http://www.3d-cam.com/http://www.3de.net/http://www.rapid-design.com/http://www.rapidsolutions.com/http://www.rpc.fi/http://www.quickparts.com/http://www.prototech.com/http://www.prototechengineering.com/


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REFERENCES

http://www.atirapid.com/tech/te_rpservices.html

http://www.wohlersassociates.com/

http://www.zcorp.com/ http://www.nait.org/jit/Articles/steir120800.pdf

http://home.att.net/~castleisland/fdm_int.htm

Rapid Prototyping DirectoryComprehensive directory

Worldwide Guide to Rapid PrototypingListings for about 500 service bureaus,

as well as other RP reference information. www.photopolymer.com/

http://ltk.hut.fi/~koukka/RP/rptree.html#SL
http://www.atirapid.com/tech/te_rpservices.htmlhttp://www.wohlersassociates.com/http://www.zcorp.com/http://www.nait.org/jit/Articles/steir120800.pdfhttp://home.att.net/~castleisland/fdm_int.htmhttp://www.cadcamnet.com/http://home.att.net/~castleisland/http://ltk.hut.fi/~koukka/RP/rptree.htmlhttp://ltk.hut.fi/~koukka/RP/rptree.htmlhttp://home.att.net/~castleisland/http://www.cadcamnet.com/http://home.att.net/~castleisland/fdm_int.htmhttp://www.nait.org/jit/Articles/steir120800.pdfhttp://www.zcorp.com/http://www.wohlersassociates.com/http://www.atirapid.com/tech/te_rpservices.html


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Bradleys LOM System

Helisys (1991 - 2000)A staple at the early rapid prototyping shows, Helisys consistently drew large, interestedcrowds to its LOM technology. Through the years, Helisys had placed more than 375 systemsinto service. Yet, in November 2000, the company folded. Helisys' challenges came from two

different directions - technological and marketing. Like Cubital and BPM, Helisys had some reliability and maintenance issues in the earlier years.

Although they worked to overcome the problems and did so successfully, the reputation stuck.You can still hear people state, "Wasn't that the company who's machines caught fire?" In thesmall world of rapid prototyping, reputations are quickly created and difficult to shed.

The business mistake that Helisys failed to see was that they did not heed the tenet to find aniche and conquer it. The LOM process was best suited for thick walled applications, likepatterns for sand or investment casting. But, the market was demanding functional prototypes

and prototypes for injection molded products. Helisys was quick to proclaim "me too." Trying to be everything to everyone caused Helisys to lose its focus on the company's core

competency. It also caused them to sell systems into unsuitable environments. This, in turn,created dissatisfied customers - another reputation that was hard to shed.

In the later years, Helisys regrouped and retrenched to return to the application that hadcreated earlier success. But it was too late.

Rapid Pro to Typing Case Study

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