Rapid Prototyping

Rapid prototyping takes virtual designs from computer-aided design (CAD) or animation modeling software, transforms them into thin, virtual, horizontal cross-sections and then creates each cross-section in physical space, one after the next until the model is finished. It is a WYSIWYG process where the virtual model and the physical model correspond almost identically.

With additive fabrication, the machine reads in data from a CAD drawing and lays down successive layers of liquid, powder, or sheet material, and in this way builds up the model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are joined together or fused automatically to create the final shape. The primary advantage to additive fabrication is its ability to create almost any shape or geometric feature.

The standard data interface between CAD software and the machines is the STL file format. An STL file approximates the shape of a part or assembly using triangular facets. Tiny facets produce a higher quality surface.

The word "rapid" is relative: construction of a model with contemporary methods can take from several hours to several days, depending on the method used and the size and complexity of the model. Additive systems for rapid prototyping can typically produce models in a few hours, although it can vary widely depending on the type of machine being used and the size and number of models being produced simultaneously.