Toward generic models for comparative evaluation and process selection in rapid prototyping and manufacturing

Selection of the most suitable rapid prototyping and manufacturing (RP&M) process for a specific part creation is a difficult task due to the proliferation of RP/s&M processes and materials. Multiple considerations such as good dimensional accuracy, fine surface finish, short building time, and low building cost are all desired objectives, and no one process is superior in all aspects. For a software tool to assist in making such a selection, a systematic study is first required to compare pertinent attributes among the different RP&M processes. It is also necessary to design appropriate models that can be used to characterize these attributes and that can be modified for existing and future RP&M machines. This paper studies the four dominant RP&M processes currently in the market—stereolithography (SL), selective laser sintering (SLS), fused deposition modeling (FDM), and laminated object manufacturing (LOM)—through a benchmark part. Generic models for surface roughness, building time, and building cost are also presented.