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Keywords
Rapid prototyping, Costs, Manufacturing
Abstract
Introduces the concept of using technologies collectively known as rapid prototyping (RP) for the manufacture of end-use products rather than prototypes, and presents recent examples. Gives details of a cost analysis performed by De Montfort University and Delphi Automotive Systems (France). Discusses the findings from the cost analysis along with opinions generated from an Internet based conference held from November 2000 to January 2001. The combination of findings from the cost analysis with expert opinions generated by the Internet conference have helped to identify the potential future for rapid manufacturing. In particular covers the issues of material properties, quality control and identification of suitable products.
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Introduction
The idea of using rapid prototyping (RP) machines for the manufacture of products in high or medium volumes initially seems unrealistic as cycle times, materials costs and capital equipment for processes such as injection moulding are generally far lower than those for RP. However an appreciation that zero tool costs, reduced lead times and considerable gains in terms of freedom in product design and production schedules may significantly benefit manufacturing will help in accepting the potential benefits to be gained.
Definitions
The title of this paper contains a clear paradox in the use of the words "prototyping" and "manufacture" so let us get things clear from the start:
RP refers to a group of commercially available processes which are used to create solid 3D parts from CAD, from this point onwards these processes will be referred to as layer manufacturing techniques (LMTs).
Rapid manufacturing uses LMTs for the direct manufacture of solid 3D products to be used by the end user either as parts of assemblies or as stand-alone products.
Recent examples of rapid manufacturing
Boeing's Rocketdyne propulsion and power section has used selective laser sintering (SLS) to manufacture low volumes of parts such as for the space lab and space shuttles (Rapid Prototyping Report, 1999). NASA's Jet Propulsion lab has also used SLS to make parts launched into the upper atmosphere[1]. Align Technologies use stereolithography (SL) to produce one-off...