Analysis of rapid manufacturing—using layer manufacturing processes for production

TLDR

Rapid prototyping technologies, developed over the past 15 years, create 3‑D geometries from CAD by stacking 2‑D layers, and while currently mainly used for prototyping or tooling, they are increasingly viewed as viable processes for producing end‑use products, a concept termed rapid manufacturing. This study compares the unit cost of injection moulding with that of stereolithography, fused deposition modelling, and laser sintering for parts produced in various quantities. The authors performed a cost analysis of injection moulding versus layer manufacturing processes, evaluating unit costs across different production volumes. For certain geometries, layer manufacturing methods are more cost‑effective than injection moulding when producing thousands of parts.

Abstract

Rapid prototyping (RP) technologies that have emerged over the last 15 years are all based on the principle of creating three-dimensional geometries directly from computer aided design (CAD) by stacking two-dimensional profiles on top of each other. To date most RP parts are used for prototyping or tooling purposes; however, in future the majority may be produced as end-use products. The term ‘rapid manufacturing’ in this context uses RP technologies as processes for the production of end-use products. This paper reports findings from a cost analysis that was performed to compare a traditional manufacturing route (injection moulding) with layer manufacturing processes (stereolithography, fused deposition modelling and laser sintering) in terms of the unit cost for parts made in various quantities. The results show that, for some geometries, it is more economical to use layer manufacturing methods than it is to use traditional approaches for production in the thousands.