Published Article / Long-term growth in the additive fabrication industry will come from designs that are difficult, time-consuming, costly, or impossible to produce using standard techniques. Growth will occur with advances in the current additive processes, coupled with breakthroughs in new materials, which are expected to emerge over the next five to 10 years. These advanced materials will better satisfy the design requirements of many new products. The paper considers currently available technologies and discusses recent advancements in direct metal freeform fabrication and its potential of revolutionising the medical industry.

Published Article / The paper presents a critical review of the techniques that are used to cool plastic injection moulds. It examines research on cooling of injection moulds by conventional cooling, the benefits and the limitations of the method. It compares the deployment mechanisms that have been proposed by various researchers. It also examines how the various mechanisms affect the plastic cooling rate and the overall heat transfer performance of the mould and how the various deployments affect the stress distribution of the mould and mould durability. The paper also presents the possibilities that have been presented by rapid prototyping. It discusses the development of conformal cooling as an alternative to conventional cooling. It presents the state of the art on the method. The paper presents the deficiencies in the current theories on conformal cooling and suggests areas that require further work in order to fully exploit the technique.

Published Article / This article looks at the role that vacuum casting plays in the rapid prototyping and rapid manufacturing process. The accuracy to which components can be reproduced, by looking at the controllable factors in the casting process and the different types of materials that are available, were investigated and the process was also compared to other rapid prototyping and manufacturing processes in terms of cost effectiveness. Castings were made from a typical component under different operating conditions and the characteristics of the cast component, dimensions strength and surface hardness, were measured and plotted to determine the characteristics and accuracy of the process.

Published Article / Over the past few years, methods of layered manufacturing (LM) have advanced substantially to the point where they now provide vital strategic benefits to various organisations. One area of application where LM technologies have begun to reach a critical mass is in the development and production of high-performance tooling in different forming processes. With these tooling capabilities now available, the next challenge becomes the development of optimal process chains to minimise lead times and production costs, while still ensuring high quality of castings. The relevant issues that influence where a break-even point will be between different process chains and thereby also the point of selection between such optimal process chains according to different situations include among others: <ul> <li> the size of production runs, </li> <li> part size and complexity, and</li> <li> the cast materials involved.</li> </ul> <br>This paper reflects some of the experiences gained from an investigation towards developing a set of generic rules (guidelines) for the design of optimal process chains for sand casting prototypes of automotive components using LM methods, and more specifically the 3D Printing process.

Published Article / This paper looks at the development of composite materials in layered manufacturing. It is known that Rapid Prototyping (RP) using a single material compares poorly with other conventional manufacturing processes when making parts from similar materials. For example, injection moulded parts are over 30% stronger than RP fabricated parts of the same material. The incorporation of secondary materials can result in a composite that can improve this situation. This paper will discuss different composites that are commercially available as well as some into which research is being conducted. An advantage of RP is that composites do not have to be manufactured in a homogeneous manner. Functionally graded parts may be fabricated where reinforcing material can be added in appropriate locations and in required orientations.

Published Article / This paper identifies the most significant technological developments made in medical applications of rapid prototyping and manufacturing (RP&M) over the past decade. This assessment is based on a retrospective analysis of the research undertaken by the Medical Applications Group of the National Centre for Product Design and Development Research (PDR), based at the University of Wales lnstitute Cardiff (UWIC). UK. The paper describes the state of technology at the inception of the Group in 1998 and then highlights the significant technological developments that impacted on the activities of the Group over the decade to 2008. The paper will also discuss how these technologies have developed since their initial implementation. The paper will conclude with suggested directions future work should take in order to meet clinical and technical needs.

Published Article / Current fused deposition modelling (FDM) technologies deposit material as flat layers. The result is a "stair-case" effect on non-vertical or horizontal surfaces, and compromised part strength because of weakness between the laminations. This paper describes an FDM method through which layers of build material are deposited as curved layers following the shape of the part, thus removing the stair-case effect and creating parts that have an even strength distribution over their entire surface. Support material is first deposited as conventional flat layers, and build material is then deposited over the support structure following the curves of the part. The paper discusses a proof of concept of the system, the algorithms used to generate the curve paths for the deposition head, and examines the challenges and possibilities of this technology, including the capability of including composite materials.

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