Wohlers Associates

Wohlers Report 2004

Rapid Prototyping & Tooling State of the Industry
Annual Worldwide Progress Report ISBN 0-9754429-0-2

Acknowledgments
About the author
Focus of this report
Introduction to rapid prototyping

History of RP Systems
- Introduction of non-SL systems
- Initial introduction of 3D printers
- New generation machines
Industries being served
- How RP models are being used
- Installations by country
Applications
- Communication
- Engineering changes
- Good ideas and powerful proposals
- Concept models
- Verifying CAD databases
- Styling, ergonomic studies
- Functional testing
- Prototypes
- Metal castings
- Early input from suppliers, toolmakers
- Quote requests
- Tooling
- Rapid manufacturing
- Unlimited potential

Advances
- Growing list of methods
- Improved thermal management
- Risk factors
Indirect approaches
- Silicone rubber tooling
- Epoxy-based composite tooling
- Spray metal tooling
- RSP Tooling
- Ford Sprayform
- Cast kirksite tooling
- RPM (rubber plaster mold) casting
- 3D Keltool
- PolySteel
- MetalCopy
- Swiftool
- PHAST
- V-Process
- Reconfigurable Tooling Systems
- Others
Direct approaches
- SL tooling
- SLS tooling
- DMLS
- POM
- Others
Other options
- CNC-machined tooling
- Laminate tooling
- Hybrid tooling
- Space Puzzle Molding
Tool design software
- Magics Tooling
- FlashTL Mould
- Other products
Size of tooling market
- Aluminum tooling
- Projected growth rates
- Metal part fabrication
Tooling comparison matrix

3D Systems
- New management
- Settlement
- New products
- Other developments
Arcam
Beijing Yinhua
Concept Laser
Cubic Technologies
Envisiontec
EOS
- New products and applications
- Settlement with 3D Systems
F&S/MCP
Objet Geometries
- Partnership with Stratasys
- Eden330
- Eden260
Optomec
Phenix Systems
POM
- DMD 505
- Technology strengths
ProMetal
Sanders Design International
Shanghai Union Technology
Solidica
Solidscape
Sony
Stratasys
- Dimension
- Partnership with Objet
- Other systems, materials
- Outlook
Trumpf
Wuhan Binhu
Z Corp.
- Unit sales
- Materials
- Distribution
3DP licensees
- Therics
- Soligen
- Metal Matrix Cast Composites
- Specific Surface
Others
- Schroff
- Helisys
- Cubital
- Röders
- BMT
Real cost of RP
RP stocks
- Revenues and earnings
- Trends and areas of interest
- Outlook

Patents
Technology developments
- Photopolymers
- Deposition
- Lamination
- Powder systems
- Other additive and subtractive methods
- Computational advances
- Other advances
U.S. government-sponsored R&D
- National Science Foundation
- Educational funding
- Gradient and multi-materials support
- Biomedical research
- Meso, micro, and nano scale technology
- Other NSF-funded projects
- Department of Commerce
- Department of Health and Human Services
RP academic programs
- RP educational activities
- Basic research activities
- Applied research activities
- Future trends and contributions

What is it?
Benefits
- Product design
- Materials
- Custom products
- Prototyping and production
- Manufacturing location
Applications and industries
- Air ducts for fighter jets
- Sintered parts for space
- Formula 1
- Military tanks
- Hearing instruments
- Centrifuge
- Submarine part
- Computer lock
- Lamp designs
- Other possibilities
When it makes sense
- Shape and size
- Production volume
- Quality
Cost analysis and economics
- Production implications
- Strategic implications
Challenges and needed research
- Processes
- Materials
- Product design
- Organization, management, and supply chain issues

Growth of solid modeling
- Revenue and seat count estimates
- Solid business
- New potential markets
RP materials
- SL resin developments
- Discount supplier
- Laser-sintering powders
- Metal materials for sintering
- EOS Alumide
- FDM materials
- New Objet materials
- Materials from Z Corp.
- Material for InVision
- Envisiontec Perfactory
- Predicting the performance of injection-molded parts
Medical modeling
- RP equipment and medical scanners
- Transferring the medical scan data
- Material options
- Research and development
- Conjoined twins
- Egyptian case
3D digitizing and reverse engineering
- Applications
- Clay model acquisition
- Competitive assessment
- Manufacturing surface comparison
- Inspection
- Technology
- 3D digitizing
- Limitations and other important issues
- Triangle meshes and surfaces
- Caveats

Exciting times
Analysis process
3D printers for concept modeling
- Factors affecting demand
- Changes in technology and prices
- Changing materials
- Product development
- Who will buy them?
Rapid prototyping systems for plastics
- Market demand
- Technology, pricing, and materials
- Design and manufacturing
- Who are the customers?
RP systems for metals
- Demand for metal parts from RP
- Technology and pricing
- Changes in product development and manufacturing
Rapid manufacturing systems for plastics
- Market demand
- Changes to design and manufacturing
- Who are the buyers?
Rapid manufacturing systems for metals
- Market demand
- Changes in product development
Summary
Where to learn more
- Global Alliance of Rapid
- Prototyping Associations
- Rapid Technologies and Additive Manufacturing Community