Rapid prototyping is coming of age

This article examines how, by accelerating the design process and speeding tooling development, rapid prototyping technology helps manufacturers cut new product cycle times and costs. During the last decade, a class of technologies has emerged by which a computer-aided design file of an object can be converted into a physical model through special sintering, layering, or deposition techniques. Called rapid prototyping (RP), or solid free-form fabrication, the major application for this technology has been early verification of product designs and quick production of prototypes for testing. Multiple prototypes can now be reproduced more economically by using the RP master as a pattern for creating molded or soft tooling. Interest in desktop (or more accurately, office) rapid prototyping for visualization and design verification is growing, but it is not yet easy to cost-justify. Recently, the fabrication of patterns for limited-run production tooling has become more common. Today, the most popular rapid tooling options are silicone rubber (RTV) molding and epoxy and spray metal tooling. For metal part production, the choices are investment, plaster, spin, and sand casting.