Rapid prototyping (RP) and tooling (RT) technologies have attracted tremendous R&D interests from both academia and industry in the since the 1990s. More recent interests in RP technologies are towards functional applications of the fabricated parts, such as in rapid tooling applications and replacements of damaged components. Many RP processes and materials have been commercialized but are yet to be able to fulfil the functional requirements because of limited mechanical strengths of fabricated parts. This book thus focuses on the fundamental issues of the laser-induced RP materials and processes. The remedies and possible solutions to RP/RT pertaining to materials and processes are included. The highlighted research issues and presented results are not only informative, but should also be very useful for future commercial developments.
1 Introduction.- 1.1 Overview of rapid prototyping and manufacturing.- 1.2 Laser-induced rapid prototyping.- 1.3 RP process characterization and modeling.- 1.4 RP technology trends.- 1.5 References.- 2 Fundamentals of Laser-lithography Processes.- 2.1 Laser-lithography.- 2.2 Laser scanning in LL process.- 2.3 Fundamental relationships.- 2.4 Characteristics of photo-polymerization.- 2.5 Summary.- 2.6 References.- 3 Material Characterization of Laser-lithography Built Parts.- 3.1 Mechanical properties of LL parts.- 3.2 Analyses of degree of curing.- 3.3 Distortion analysis by Moire method.- 3.4 Summary.- 3.5 References.- 4 Improvements of Mechanical Properties by Reinforcements.- 4.1 Introduction.- 4.2 Fiber-reinforced photo-polymer.- 4.3 AEROSIL-mixed photo-polymer.- 4.4 Improvements in LL-process.- 4.5 Summary.- 4.6 References.- 5 Selective Laser Sintering.- 5.1 Principle of laser sintering.- 5.2 Process of selective laser sintering.- 5.3 Liquid phase sintering in SLS.- 5.4 Commercial applications.- 5.5 Metal powders for laser sintering.- 5.6 Densification.- 5.7 Mechanical property.- 5.8 Summary.- 5.9 References.- 6 Metal-Based System via Laser Melting.- 6.1 Selective laser melting process.- 6.2 Metal powders.- 6.3 Composites.- 6.4 Summary.- 6.5 References.- 7 Laser Sintering of Ceramics.- 7.1 Fabrication of ceramic parts using SLS.- 7.2 SLS of ceramic parts.- 7.3 Summary.- 7.4 References.- 8 Characterization, Modeling and Optimization.- 8.1 Introduction.- 8.2 Modeling of RP part fabrication.- 8.3 Optimal orientation.- 8.4 Direct slicing of CAD models.- 8.5 Decision support for process optimization and selection.- 8.6 Summary.- 8.7 References.- 9 Rapid Tooling and Its Applications.- 9.1 Rapid tooling development.- 9.2 Rapid tooling techniques and applications.- 9.3 RT for injection molding - a case study.- 9.4 Application to EDM electrode fabrication.- 9.5 Summary.- 9.6 References.