There can be few more exciting developments in manufacturing and design than the new techniques of rapid prototyping, tooling and manufacturing. The aim of these processes is to take a new product from the Computer Aided Design (CAD) stage into instant production of the prototype, or even the end use part. In this report the different methods available, the material choice, accuracy and model build size are described, providing an excellent overview of these topics for engineers, designers and manufacturers.

There are several different methods for the rapid production of prototypes. They entail depositing material in progressive layers as defined by a CAD program. Stereolithography is the most widely used technique, and utilises the photopolymerisation of light-sensitive liquids by laser scanning. Selective laser sintering is similar, but uses powder instead of liquid. Fused deposition modelling entails the extrusion of either wax or plastic through a moving nozzle onto a mobile platform. Solid ground curing is a combination of stereolithography, fused deposition modelling and computer numerical control (CNC) milling. Laminated object manufacturing involves building up an object by laying down sheets of material and cutting each sheet to the required shape; the layers are then bonded or clamped together.

Concept modellers are a new generation of rapid prototyping machines. These are aimed at the design office. The theory is that when a designer requires a model, the modelling machine will take the CAD file and print a 3-dimensional hard copy within a few hours.

Rapid tooling describes any method which produces moulding tools quickly. Rapid prototyping techniques can be used to make tools directly or indirectly. In the latter instance the prototype can be used as a positive or a negative pattern for making the tool, sometimes two or three stages are involved. The concept of soft versus hard tooling is defined. Production methods and applications of tools in materials such as silicone rubber, epoxy resin, plaster, ceramics, steel and sprayed metal are outlined.

Rapid manufacturing is the future of rapid prototyping. The new techniques permit easier production of complex shapes, and reduce assembly requirements. Soon end use parts may be made using rapid prototyping techniques without the need for any tooling, generating truly flexible manufacturing.

The authors of this report work for Edward Mackenzie Consulting, and specialise in delivering bespoke academic and industrial information in the fields of rapid prototyping and tooling, mass customisation, advanced manufacturing and time-to-market. Dr. Hague received the first PhD in the UK specifically within the field of rapid prototyping and tooling.

This review of rapid prototyping, tooling and manufacturing is accompanied by an indexed section containing more than 400 references and abstracts from the Polymer Library.