RAPID PROTOTYPING

ABSTRACT The term rapid prototyping (RP) refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data. It is also called Desktop Manufacturing or Freeform Fabrication. These technologies enable us to make even complex prototypes that act as an excellent visual aid to communicate with co-workers and customers. These prototypes are also used for design testing. Why Rapid Prototyping? Objects can be formed with any geometric complexity or intricacy without the need for elaborate machine set-up or final assembly. Freeform fabrication systems reduce the construction of complex objects to a manageable, straightforward, and relatively fast process. These techniques are currently being advanced further to such an extend that they can be used for low volume economical production of parts. It significantly cut costs as well as development times.

The Basic Processes RP is basically a five-step process.

1. 2. 3. 4. 5.

Create a CAD model of the design Convert the CAD model to STL format Slice the STL file into thin cross-sectional layers Construct the model one layer atop another Clean and finish the model

RAPID PROTOTYPING TECHNIQUES RP Techniques have proven to be more convenient in building complex prototypes. This is because these processes are additive in nature unlike conventional subtractive processes. At least six different rapid prototyping techniques are commercially available, each with unique strengths.

S T L - Stereolithography

STEREOLITHOGRAPHY

Stereolithography was the first RPT developed in United States in 1986. It uses a photosensitive polymer that solidifies when exposed to UV light. The model is built upon a platform situated just below the surface in a vat of liquid epoxy or acrylate resin. The object is built layer by layer. A low power highly focussed UV laser is used to solidify the first layer leaving the excess areas liquid. This processes is repeated until the desired shape according to the CAD model is obtained. LAMINATED OBJECT MANUFACTURING

Laminated Object Manufacturing In LOM layers of adhesive-coated sheet material are bonded together to form a prototype. The model material consists of paper laminated with heat-activated glue. The paper is pressed on to the base using a heated roller. A focused laser cuts the outline of the first layer into the paper and then crosshatches the excess area. The next layer is built on top of the first layer in the same manner. The hatched parts (excess area) are removed after the final layer is bonded. The final model has a wood like texture and since it is made of paper the model has to be varnished to prevent moisture damage.

Rapid Prototyping Technology

SOLID GROUND CURING

Solid Ground Curing (SGC) is somewhat similar to stereolithography (SLA) in that both use ultraviolet light to selectively harden photosensitive polymers. First, photosensitive resin is sprayed on the build platform. Next, the machine develops a photo mask (like a stencil) of the layer to be built. The mask is exposed to UV light and the exposed parts are solidified. After the layer is cured, the machine vacuums up the excess liquid resin and sprays wax in its place to support the model during the build. The top surface is milled flat, and then the process repeats to build the next layer. FUSED DEPOSITION MODELING

In this technique the heated thermoplastic is sent through an extrusion mould. The thin beads thus obtained are deposited on the build platform to form the first layer. The platform is maintained at lower temperature for the thermoplastic to harden quickly. After the first layer is formed the platform lowers and the extrusion head deposits the next layer on top of the first layer.

APPLICATIONS Prototyping Rapid Tooling Rapid Manufacturing Heterogeneous Modelling ADVANTAGES Objects having Complex geometry can be easily manufactured. Better surface finish. Materials used are cheaper. Considerable reduction in production time. Less wastage of build-materials. RP manufacturers are dramatically reducing build time.

DISADVANTAGES The polymer material has to be in a special form to be used for prototyping. Less tensile strength Not economical for manufacture of simple designs. Not suitable for small-scale production. Physical properties of the part change with method of manufacture. Since the objects are made layer by layer there is a Stair Stepping Effect. Selective Laser Melting (SLM) of metals Process Selective laser melting (SLM) is one of the new additive manufacturing techniques that emerged in the late 1980s and 1990s. During the SLM process, a product is formed by selectively melting successive layers of powder, e.g. Ti6Al4V powder, by the interaction of a laser beam. Upon irradiation, the powder material is heated and, if sufficient power is applied, melts and forms a liquid pool. Afterwards, the molten pool solidifies and cools down quickly, and the consolidated material starts to form the product. After the cross-section of a layer is scanned, the building platform is lowered by an amount equal to the layer thickness, e.g. 30 um, and a new layer ofpowder is deposited. This process is repeated until the product is completed. The nonirradiated material remains in the building cylinder and is used to support the subsequent layers. After the process, the unused powder is sieved and can be reused. To counteract curling of the material due to the build-up ofthermal stresses during the SLM process, the part is built on a solid substrate. Due to the high reactivity ofTi alloys, the process needs to be conducted under an inert argon atmosphere. A typical SLM machine layout is presented in the figure below.

Advantages Compared to conventional manufacturing techniques, SLM offers a wide range of advantages, namely a lower time-to-market, a near-net-shape production without the need of expensive moulds, a high material utilization rate, direct production based on a CAD model, and a high level of flexibility (e.g. products with different geometry can be produced in the same batch).Moreover, due to the additive and layer-wise production, the SLM process is capable of producing complex geometrical features that cannot be obtained using conventional production routes. Some examples of typical biomedical applications are illustrated below. Disadvantages Unfortunately, this new production technique has to deal with some frequently observed problems. SLM is characterized by high temperature gradients, which results in the buildup of thermal stresses, and a rapid solidification, which gives rise to the occurrence of segregation phenomena and the presence of non-equilibrium phases. The stability, dimensions and behaviour of the melt pool will determine to a great extent the porosity and the surface roughness, other than the roughness created by the layerwise building (i.e. the staircase effect). The limited availability of some particular materials in powder form and the extensive research that still is needed to optimize the process for a given material also restrict the material range that can currently be processed. Direct Metal Laser Sintering Direct Metal Laser Sintering (DMLS) is an additive manufacturing technology that produces metal prototype and production parts in a matter of hours.DMLS utilizes a variety of metal and alloy materials to create strong durable parts from 3D CAD data without the need of tooling. Metal parts built with this technology have the design versatility of layer additive manufacturing while possessing the mechanical properties and appearance of metal materials.

Direct Metal Laser Sintering (DMLS) was developed jointly by Rapid Product Innovations (RPI) and EOS GmbH, starting in 1994, as the first commercial rapid prototyping method to produce metal parts in a single process. With DMLS, metal powder (20 micron diameter), free of binder or fluxing agent, is completely melted by the scanning of a high power laser beam to build the part with properties of the original material. Eliminating the polymer binder avoids the burnoff and infiltration steps, and produces a 95% dense steel part compared to roughly 70% density with Selective Laser Sintering (SLS). An additional benefit of the DMLS process compared to SLS is higher detail resolution due to the use of thinner layers, enabled by a smaller powder diameter. This capability allows for more intricate part shapes. Material options that are currently offered include alloy steel, stainless steel, tool steel, aluminum, bronze, cobalt-chrome, and titanium. In addition to functional prototypes, DMLS is often used to produce rapid tooling, medical implants, and aerospace parts for high heat applications. The DMLS process can be performed by two different methods, powder deposition and powder bed, which differ in the way each layer of powder is applied. In the powder deposition method, the metal powder is contained in a hopper that melts the powder and deposits a thin layer onto the build platform. In the powder bed method (shown below), the powder dispenser piston raises the powder supply and then a recoater arm distributes a layer of powder onto the powder bed. A laser then sinters the layer of powder metal. In both methods, after a layer is built the build piston lowers the build platform and the next layer of powder is applied. The powder deposition method offers the advantage of using more than one material, each in its own hopper. The powder bed method is limited to only one material but offers faster build speeds.

Direct Metal Laser Sintering (DMLS)

Capabilities Abbreviation: DMLS Material type: Powder (Metal) Materials: Ferrous metals such as Steel alloys, Stainless steel, Tool steel; Nonferrous metals such as Aluminum, Bronze, Cobalt-chrome, Titanium; Ceramics Max part size: 10.00 x 10.00 x 8.70 in. Min feature size: 0.005 in. Min layer thickness: 0.0010 in. Tolerance: 0.0100 in. Surface finish: Average Build speed: Fast Applications: Form/fit testing, Functional testing, Rapid tooling, High heat applications, Medical implants, Aerospace parts DML S Ad van tages Creation speed and accuracy Strong and durable Fine feature detail DML S Ap p l i cati on s Functional Prototypes Tough prototypes that can be used for functional tests High-Temperature Applications Quickly manufacture parts that can withstand high heat End-Use Parts Low-volume production without tooling expense and lead times DML S I n d u stri es Medical Instruments Dental Aerospace Automotive Surgical Implants Industrial Commercial

Rapid Tooling (RT) typically describes a process which either uses a Rapid Prototyping (RP) model as a pattern to create a mold quickly or uses the Rapid Prototyping process directly to fabricate a tool for a limited volume of prototypes. Rapid Tooling can act as a bridge to production injection molded parts. We are particularly proud of our rapid tooling capabilities, and offer prices well below those typically in charged in the USA. Advantages of Taiwan product development and manufacture extend to a well-established base of local tooling expertise, matching services and quality offered by western tooling firms but with advantages of time and cost savings and flexible vendors able to respond quickly to changes and updates. We can respond quickly to requests for quotation after receipt of your CAD (ProE or IGES format) files via email or FTP transfer. Advantages:

Tooling time is much shorter than for a conventional tool. Time to first articles can be less than one-fifth that of conventional tooling. Tooling cost is much less than for a conventional tool.

Challenges:

Tool life is less than conventional production tools. Tolerances are wider than conventional tools.

Benefits of Rapid Injection Molding:

Prototypes in production material in shorter timeframes. Allows for full fit and function testing. Discover any design flaws early on. Low cost tooling allows for ease of geometry modification and design refinement. Bridge to production process--molds can run thousands of parts. Contact CPIM today to take advantage of our China rapid injection expertise.

Tooling Hard Tooling Delivery of first article samples, 4 weeks (very simple parts) 12 weeks (normal complexity) longer for complex or parts requiring ceramic core tooling Delivery of production, 2 12 weeks after First Article approval.

Highest tooling expense Lowest investment casting pattern cost Hard tooling will have the longest life. Simple tooling will last for hundreds of thousands of parts. Complex tooling with slides and cores will wear over time but can generally be refurbished. This is not normally necessary for many years. Yields the best surface finish and most consistent dimensional control. Soft Tooling Delivery of first article samples, 3 6 weeks Delivery of production, 2 12 weeks after First article approval Soft tooling is less costly than Hard Tooling Pattern cost is higher than Hard Tooling. This is because the tooling will cycle slower due to the poor thermal conductivity of mold material Life of soft tooling is limited. Life will depend upon the complexity of part. The more complex the shorter the life Surface finish and dimensional control is not as good as Hard Tooling A single SLA (stereolithography) or Objet pattern is generally used to make the tooling SOLID MODELING Design is a creative activity to transform ideas into reality. With the advent of softwares for creation of CAD Solid Models , the visualization of ideas has become possible in the design stage itself and such Solid Models can also be converted to 2D drawings which in turn reduces the product development cycle time. There are different software available at CMERI, for CAD Solid Model creation which comprise I-DEAS, UG, Pro-Engineering, CATIAand so on.

Applications Solid Models also help in checking assemblies and interferences, mass properties

calculations, mechanism analysis, tolerance analysis and strength analysis. Subsequently with development of the Rapid Prototypingmachines, the Solid Models can be directly used for development of physical models, without necessitating any process planning. With the development of Tool Path Generation software, Solid Models can also be used directly to generate the Tool Paths for machining of moulds, dies etc. Basic Functions in Parametric Solid Modeling Before discussing PSM in more detail, the reader should be familiar with the basic operations which can be used to make a solid model of a part/product. Note that when applicable, the illustrations below start out with a 2D sketch, then are transformed into 3-D geometry. The basic process may differ somewhat, depending on the CAD program you use. Function What its good for Process

Solid Extrusions are often used to:

Make the base part of a model Adding bosses/features to a model

Solid Extrusion Subtracting portion of a model to form a feature like:

1. Pick/make a sketch plane 2. Draw & dimension a 2-D sketch 3. Issue "extrude boss" command 4. Define extrusion type (blind, midplane, etc....) 5. Enter extrusion depth if necessary 1. Pick/make a sketch plane 2. Draw & dimension a 2D sketch 3. Issue "extrude cut/slot" command 4. Define extrusion type 5. Enter extrusion depth if necessary

Holes Keyways Cavities

Cut/Slot Extrusion

Adding features to a model which can best be described in Rcoordinates. These features include:

Revolved Extrusion

Base of a model External pipes/ducts Torous shaped features Annular features/ribs

1. Pick/make a sketch plane 2. Draw & dimension a 2D sketch 3. Draw a centerline around which to revolve 4. Issue "revolve cut/slot" command 5. Enter revolution if necessary

Subtracting a portion of a model which can best be described in Rcoordinates. These features include:

Revolved Cut

Internal pipes/ducts External irregular shaped grooves

1. Pick/make a sketch plane 2. Draw & dimension a 2D Sketch 3. Draw a centerline around which to revolve 4. Issue "revolve cut/slot" command 5. Enter revolution if necessary

Adding/subtracting features to a model where two ends of the feature are described by different xsections (sketches) and the x-sections must transform into each other. Loft

1. Pick/make a sketch plane 2. Draw & dimension 1st sketch 3. Draw & dimension 2nd sketch 4. Issue "loft command"

Base of a model External features 1. Pick/make a sketch plane 2. Draw & dimension sweep path 3. Draw & dimension sweep x-section 4. Issue "sweep"

Adding or subtracting parts to/from a model which can best be described by "sweeping" a x-section along a pre-described path:

Base of a model

Sweep

External pipes/ducts Springs Torous shaped features Annular features

command

Making thin parts such as:

Cups Bowls Thin casings

1. Issue "shell" command 2. Pick a cut plane/face/surface 3. Pick shell direction/properties 4. Pick shell thickness

Shell Direct Tooling Direct AIM Tools Direct AIM (ACES Injection Moulding) is the process whereby tools are created directly on an SLA machine. The tools are initially designed using CAD software and the process involves creating a part by SLA which is basically a shell on the underside. The purpose of the shell is to leave a cavity so that each half of the mould can be filled with a backing material such as an epoxy resin, metal or ceramic. By backfilling the mould a thermal conduit is provided for the heat exchange process and it is also possible to add any cooling channels to the mould at this stage.[4] The surface of the moulds is finished to improve the quality of the surface. Using this method it is possible to create up to 100 parts with an accuracy of 0.15 - 0.3mm. Typical application for this type of tool would be for smaller parts, mainly prototype injection moulding tools, low volume wax injection tooling and low volume foundry patterns.[5] Advantages
o

A relatively fast process - a mould can be designed and built within a 2 week period. Cheap process for small tools, such as mobile phone and mp3 player casing. Building large parts on an SLA machine is not cheap.

Disadvantages
o

A CAD model of the tool is required as this has to be saved as an stl file in order for the SLA machine to build the 3D tool. Low durability - the complexity of the tool and thermoplastic material used to build the tool all affect its life cycle. Moulds produced this way can create as little as 10 parts. Moulds typically degrade gradually with each part that is moulded on it.

Indirect Tooling Rigid Cast Resin Tooling This process manufactures a tooling insert using aluminium filled epoxy resin as the tool material. A master RP model is initially manufactured and the part is set up on a split line. The resin is then cast onto the model which is within a bolster. The resin is then left to cure, a release coat is applied to the mould, the shut-off material removed and the process is repeated for the other half of the mould. When both halves of the mould have cured, the shut off material is removed and a bolster and ejector pins are added.2,4 Typical application for this type of tool would be a small sized tool, low volume RIM (Resin Injection Moulding) tools or low volume press tools. Accuracy of the tool is dependent upon each step within the process so shrinkage and deformation must be taken into account when reviewing the overall accuracy. Advantages
o o o

Quick to produce, 2-3 days. Cost is typically 40% less than with conventional tooling.[7] Quick repair on tools is possible.

Disadvantages
o o o o

Flash can occur resulting in more effort required to trim mouldings. Difficult and slow to mould Fragile and easy to break. Repairs are not long lasting.

Distortion is possible with larger tools due to exothermic processes.

Laminated Tooling Laminated tooling is very similar to the LOM (Layer Object Manufacturing) process as slices of a CAD model are replicated by layers of cut sheet metal. The steel laminations are laser cut or cut with a water jet. Tooling inserts are initially designed using CAD software; the CAD model must represent the cavity of the tool in order to produce the mould. The slices of the cavity are cut in sheet metal which has a thickness of 1mm and then bonded, clamped or brazed together. The use of a thick laminate results in a poor surface finish so the tool must be finish machined.3 Typical application for this type of tool would be large complex tools and aerospace tooling.2 Advantages
o o o o o

Efficient use of material due to layers being cut to the exact size required. Conformal Cooling channels can be built into the tool easily if required. Standard steel sheet is used, making the process relatively quick and cheap. Good for large tools - up to 2000 x 1000 x 500mm Design of parts can be easily changed by replacing a laminate layer as long as it has not been bonded.

Disadvantages
o

Tools have to be finish machined to remove the step like features to obtain accuracy. The joints between each lamination provide the tool with a weak link. Part complexity is dependent upon layer thickness.

o o

Rapid Prototyping Glossary 3-Dimensional Printing (3DP): A rapid prototyping process developed at the Massachusetts Institute of Technology (MIT). Layers of powder are bonded by inkjet to form a part. The term is also used generically as synonym for rapid prototyping. 3D printer / 3D printing: Refers generally to the low-cost segment of the rapid prototyping machine market. The output of these systems is typically considered adequate for concept and

appearance modeling, but may lack the accuracy or other attributes of more costly systems. This terminology is used extensively in the Wohlers Report, but others may not draw as fine a distinction. Absolute Accuracy: Defined as the difference between an intended final dimension and the actual dimension as determined by a physical measurement of the part. In addition to those for linear dimensions, there are accuracy specifications for such features as hole sizes and flatness. Adaptive Slicing: The use of variable layer thickness in an additive fabrication process, generally thinner layers being used where part detail is greatest. Additive Fabrication: Fabrication of a part by adding materials to a substrate or previously formed portions of a part. The most common additive fabrication methods utilize a layered approach, but other geometries are possible. The term is also used generically as a synonym for rapid prototyping. Advanced Digital Manufacturing (ADM): 3D Systems' trade name for direct manufacturing or direct fabrication. Often used in conjunction with the company's OptoForm technology. Anisotropic: Refers to the fact that parts may have different physical properties depending on which direction measurements are made, and such differences can also arise if the exact same part is made in a different way. This can happen if the building orientation of the part in the machine is changed, and also from the sequence in which the part's elements are fabricated. Ballistic Particle Manufacturing (BPM): A rapid prototyping process which deposits materials by means of inkjet technology. At one time the term was used to refer to a specific company's technology, BPM, Inc., now defunct, but prior to that it was an early generic term for inkjetbased RP. The term is not often used at present. Bridge Tooling: Tooling which is typically capable of producing quantities of several tens to several hundreds of parts. That is to say, it "bridges" the quantity between very low volume prototype tooling and full production tooling. In some cases bridge tooling may offer sufficient volume to meet production requirements. Brown Part: A part which has been sintered or had other secondary operations performed on it to bring it from the loosely-bonded, as-formed "green" state. Parts in the brown state are generally dimensionally stable, but are often porous and usually must be infiltrated with another material before use.

Computer Numerical Control (CNC): Refers to a machine tool which is operated under automatic control, as opposed to manually by an operator. Computer-Aided Design (CAD): Also sometimes called computer-aided drafting, is a computer program which implements the functions of geometric design, drafting and documentation. Computer-Aided Engineering (CAE): A computer program which automates one or more engineering analysis functions to determine the mechanical, thermal, magnetic or other characteristics or state of a system. CAE programs may use a geometry definition from a CAD program as a starting point, and usually utilize some form of finite element analysis (FEA) as the means to perform the analysis. Computer-Aided Manufacturing (CAM): A computer program that generates tool paths or other manufacturing data to fabricate tooling, usually by subtractive means. CAM programs may use a geometry definition from a CAD program as a starting point. Concept Model / Conceptual Model: A part intended primarily for form or appearance study, but which typically cannot be used to either check fit to other parts, or provide functionality of the final part in an application. Conformal Cooling: Cooling lines in an injection molding tool that closely follow the geometry of the part to be produced. Desktop Manufacturing (DTM): An early synonym for rapid prototyping, but no longer in current usage. DTM Corp., now incorporated into 3D Systems, was named after this terminology. Use of DTM as a company name became more common usage than the prior technical definition itself. Direct (Fabrication) Processes: Generally refers to tooling which is made directly by a rapid prototyping system, as opposed to using the RP part as a pattern in a secondary process. Direct AIM tooling: 3D Systems' trade name for a process of producing injection-mold tooling directly by stereolithography. AIM stands for ACES Injection Molding, where ACES stands for Accurate Clear Epoxy Solid, another 3D trade name. Direct Composite Manufacturing: 3D Systems' trade name for OptoForm technology, a stereolithography process which utilizes paste-like photopolymers to fabricate useable parts. Direct Manufacturing: A synonym for rapid manufacturing. It refers to parts made directly for end-use by an additive rapid prototyping process.

Direct Metal Deposition (DMD):A rapid laser powder forming process commercialized by POM Group and based on research done at the University of Michigan. Directed Metal Deposition System (DMDS): Optomec's trade name for the LENS (Reg. trademark of Sandia National Labs. and Sandia Corp.) process. Direct Shell Production Casting (DSPC): Soligen is the exclusive supplier for this specialized version of MIT's three dimensional printing process (3DP). It is used exclusively for investment casting applications. Directed Light Fabrication (DLF): A laser powder forming rapid prototyping process developed by Los Alamos National Laboratory. Dots Per Inch (DPI): A measure of the resolution of a printer. The number of discrete and distinct printed marks that an instrument is capable of producing in a linear inch. Also sometimes used in RP to describe the ability of an RP system to produce discrete voxels in the X-Y axial directions. Electron Beam Melting (EBM): The Electron Beam Melting (EBM) process from Arcam is a powder-based process having a lot in common with selective laser sintering, but replaces the laser with a scanned electron beam to produce fully-dense metal parts. Electronic Marketplace: A virtual market for buyers and sellers implemented through the Internet or World Wide Web. Also known as a web exchange. Final Machining: A secondary operation in which parts formed by a rapid prototyping method are brought to acceptable final finishes and tolerances typically by subtractive CNC technology. Finish (Part Finish): A qualitative term for the appearance of a part. For example, technologies based on powders have a sandy or diffuse finish; some inkjet technologies produce a smooth finish due to use of extremely thin layers; sheet-based methods might be considered poorer in finish because stairstepping is more pronounced. Freeform Fabrication (FFF): A synonym for rapid prototyping. The term is more precise and wider in scope, and somewhat favored by the academic community. One variant is freeform manufacturing (FFM), but a more common one is solid freeform fabrication (SFF). Fused Deposition Modeling (FDM): A thermoplastic extrusion-based rapid prototyping technology provided by Stratasys. Fused Deposition of Ceramics (FDC): Fused deposition modeling using a composite material of thermoplastic or other binder containing ceramic particles or fibers.

Green Part: A part that has been formed by a rapid prototyping process, but is in a looselybonded state. For example, metal or ceramic parts formed by some selective laser sintering systems are in a "green" state when removed from the machine. They are then sintered by a secondary operation to a "brown" state. Indirect (Fabrication) Processes: Generally refers to tooling which is made by using an RPgenerated part as a pattern for a secondary process as opposed to directly fabricating a tool using the RP process itself. Initial Graphic Exchange Specification (IGES): A standard neutral format for the exchange of 2D and 3D CAD data. STEP is a follow-on to IGES and stands for Standard for the Exchange of Product Model Data. Laminated Object Manufacturing (LOM): Helisys, now defunct and succeeded by Cubic Technologies, was the first producer but also several other manufacturers provide this technology. :Layers of paper or other materials are cut and bonded to form a part. Laser Additive Manufacturing (LAM): A laser powder forming rapid prototyping process developed by AeroMet Corporation. It's mainly aimed at producing large parts from reactive materials such as titanium for aerospace applications. Laser Engineered Net-Shaping (TM) (LENS ): A rapid prototyping process which deposits metal powder into a pool of molten metal or other build material formed by a focused laser beam. There are several variants either commercially available or under development. LENS was developed by Sandia National Laboratories and commercialized by Optomec. It can also be used for repairing and modifying existing parts and tools. (LENS and Laser Engineered NetShaping (TM) are registered trademarks of Sandia National Labs. and Sandia Corp.) Liquid Metal Jet Printing (LMJP): Similar to inkjet printing where individual molten droplets are controlled and printed to specific locations. Mass Customization: A process whereby small lots of individualized parts or products are produced. The opposite of mass production whereby large numbers of identical parts or products are produced. Mesoscopic Integrated Conformal Electronics (MICE): This DARPA program is aimed at simplifying the manufacture of electronic devices and systems, and providing greater flexibility than is possible using existing technologies. In size, mesoscale devices fall between integrated circuits and surface-mount components.

Minimum Feature Size: Refers to the smallest detail of a part that can faithfully be reproduced. Mathematical definitions are usually based on a minimum curvature as a limit, but anecdotal values based on experience are more commonly utilized. ModelMaker: This is an inkjet RP method produced by Solidscape (formerly Sanders Prototypes), and the related company, Sanders International. It produces the highest accuracy and resolution of all RP methods, but is slow and has limited material choices. MultiJet Modeling: This is an inkjet RP method produced by 3D Systems, Inc. It uses a wide area head and is most often used for generating quick concept models. The materials available are wax-like plastics and accuracy is lower than that available from stereolithography. Paper Lamination Technology (PLT): A variant on laminated object manufacturing RP technology from Kira Corp. of Japan. Pattern: An object or part which possesses the mechanical geometry of a final object or part, but which may not possess the desired mechanical, thermal or other attributes of the final parts. Patterns are used in secondary processes to form tools to make parts for end-uses. Photopolymer: Material systems which change from a liquid to a solid state upon application of light (actinic) radiation. Light sources can be a laser or lamp, but related radiation-curable materials may be made solid by application of microwave or heat-based radiation sources. Photopolymers are typically complex mixtures of compounds rather than consisting of a single component. Precision: See absolute accuracy. ProMetal: An application of MIT's Three Dimensional Printing Process to the fabrication of injection molds. Steel powder layers are bonded by photopolymer selectively applied by a wide area inkjet head. QuickCast: 3D Systems' trade name for a stereolithography build style used to make investment casting patterns. Rapid Manufacturing: Refers to the process of fabricating parts directly for end-use from a rapid prototyping machine. A synonym is direct manufacturing. Rapid Prototyping: Computer-controlled additive fabrication. Commonly used synonyms for RP are: 3-Dimensional Printing, additive fabrication, freeform fabrication, solid freeform fabrication, stereolithography. Note that most of these synonyms are imprecise.

Rapid Tooling: Most often refers to the process of fabricating tools from a rapid prototyping process. Rapid tooling may utilize direct or indirect methods: In direct methods, the part fabricated by the RP machine itself is used as the tool. In indirect methods, the part fabricated by the RP machine is used as a pattern in a secondary process. The resulting part from the secondary process is then used as the tool. In recent years, the term rapid tooling has been borrowed by practitioners of industry-standard methods such as subtractive CNC to refer to the ability to streamline these processes to compete with additive technologies. Resolution: Refers to the minimum increment in dimensions that a system achieve. It's one of the main determining factors for finish, appearance and accuracy, but certainly not the only one. Reverse Engineering: The process of measuring an existing part to create a geometric CAD data definition of the part. In common non-technical usage, reverse engineering may also refer to measuring or analyzing a part or a product for the purpose of copying it. Secondary operations: Manual or machine-based operations which must be carried out on a part fabricated by a rapid prototyping system before use. Secondary operations may include, post curing, support-removal, sanding, machining, etc. Secondary process: Any one of a large number of processes such as rubber molding. Sprayform, EcoTool, etc., that utilize a rapid prototyping-fabricated part as pattern to create a final tool or part. Selective laser sintering (SLS): A rapid prototyping technology in which powders are fused laser fused layerwise by a laser. The technology produces accurate parts and models in engineering polymers, metals and polymer-coated sand for casting applications. Speed is similar to stereolithography, but material selection is wider. Solid freeform fabrication (SFF): A synonym for rapid prototyping. The term is more precise and wider in scope, and somewhat favored by the academic community. A variant is freeform fabrication (FFF). Solid ground curing (SGC): This photopolymer-based technology was provided by Cubital. The company has been dissolved, but the process may still be available from a very few companies. A xerographically-generated mask is used to cure an entire layer of photopolymer at one time. It offers good accuracy coupled with high throughput, but is considered quite expensive.

Stairstepping: A type of inaccuracy, as well as a visual appearance artifact It refers to the stepped appearance of the edges of a part, a consequence of additive fabricating a part in layers of necesarily finite thickness. STEP: A follow-on to the IGES neutral file exchange format. The acronym stands for Standard for the Exchange of Product Model Data. Stereolithography (SL) (SLA): A rapid prototyping process that fabricates a part layerwise by hardening a photopolymer with a guided laser beam. Stereolithography is frequently used as a general term for "rapid prototyping," but this is neither precise nor correct. STL: A file format used in RP to define the geometry of the part to be made. STL files are created by CAD programs by translating their native or neutral files into the STL format. The STL file defines the coordinates of numerous triangular facets that approximate the shape of an object or part. Subtractive Machining: The fabrication of a part by removing material from a stock shape of material. The stock shape may be a prismatic solid, cylinder, plate, etc. The removal of material may by cutting, turning, electro-discharge or other means. Common machinery such as millers, lathes and drills are subtractive tools. Support Structure:Many rapid prototyping machines need a means to hold in place unsupported geometries during fabrication, such as the top of a part in the shape of the letter "T." These supports are usually calculated and added to the part by the system's software and may be formed of the same material as the part, or from a different material entirely. Support structures are either mechanically removed or dissolved away in secondary operations before the part can be used. Virtual Prototyping: Computer-based prototyping without recourse to a physical part or object. Voxel: The three dimensional equivalent of a pixel. A pixel is a "picture element," and a voxel is a "volume element." A voxel may also be defined as the minimum volume that a rapid prototyping system can fabricate. Web Exchange: A virtual market for buyers and sellers implemented through the Internet or World Wide Web. Also known as an electronic marketplace.