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Purpose -The last decade has seen major advances in rapid prototyping (RP), with it becoming a multi-disciplinary technology, crossing various research fields, and connecting continents. Process and material advancements open up new applications and manufacturing (through RP) is serving non-traditional industries. RP technology is used to support rapid product development (RPD). The purpose of this paper is to describe how the Integrated Product Development research group of the Central University of Technology, Free State, South Africa is applying various CAD/CAM/RP technologies to support a medical team from the Grootte Schuur and Vincent Palotti hospitals in Cape Town, to save limbs -as a last resort at a stage where conventional medical techniques or practices may not apply any longer. Design/methodology/approach -The paper uses action research to justify the proposal of a new method to use CAD/CAM/RP related technologies to substitute lost/damaged bone regions through the use of CT to CAD to.STL manipulation. Findings -A case study where RP related technologies were used to support medical product development for a patient with severe injuries from a road accident is discussed. Originality/value -The paper considers current available technologies, and discusses new advancements in direct metal freeform fabrication, and its potential to revolutionise the medical industry.

Purpose -Not all the inventors and designers have access to computer-aided design (CAD) software to transform their design or invention into a 3D solid model. Therefore, they cannot submit an STL file to a rapid prototyping (RP) service bureau for a quotation but perhaps only a 2D sketch or drawing. This paper proposes an alternative approach to build time estimation that will enable cost quotations to be issued before 3D CAD has been used. Design/methodology/approach -The study presents a method of calculating build time estimations within a target error limit of 10 per cent of the actual build time of a prototype. This is achieved by using basic volumetric shapes, such as cylinders and cones, added together to represent the model in the 2D sketch. By using this information the build time of the product is then calculated with the aid of models created in a mathematical solving software package. Findings -The development of the build time estimator and its application to several build platforms are described together with an analysis of its performance in comparison with the benchmark software. The estimator was found to meet its target 10 per cent error limit in 80 per cent of the stereolithography builds that were analysed. Research limitations/implications -The estimator method was not able to handle multi-component complex parts builds in a timely manner. There is a trade-off between accuracy and processing time. Practical implications -The output from the estimator can be fed directly into cost quotations to be sent to RP bureau customers at a very early stage in the design process. Originality/value -Unlike all the other build estimators that were encountered, this method works directly from a 2D sketch or drawing rather than a 3D CAD file.

Abstract

Purpose -The purpose of the present work is to develop a methodology to manufacture patient-specific models (lead masks) to be used as protective shields during cancer treatment, using 3D photography, rapid prototyping (RP) and metal spraying. It is also intended to reduce the trauma experienced by the patient, by removing any physical contact as with conventional methods, and also to reduce the manufacturing lead time. Design/methodology/approach -Patient-specific data are collected using 3D photography. The data are converted to.STL files, and then prepared for building with an LS 380 in nylon polyamide. Next, the sculpted model is used as the mould in a newly patented metal-spraying device, spraying liquid metal on to the sculpted surface. Findings -Intricate body geometries can be reproduced to effectively create metal shields, to be used in radiography applications. The models created fit the patients more accurately than through conventional methods, reducing the trauma experienced by the patient, and in a reduced time-frame, at similar costs to conventional methods. The new process and its materials management are less of a an environmental risk than conventional methods. Research limitations/implications -Access to 3D photography apparatus will be necessary, as well as to RP or CNC equipment. Using this approach, files can be transferred to a central manufacturing facility, i.e. hospitals or treatment units do not need their own facilities. Added implications are the design of jigs and fixtures, which will ensure accuracy in reuse. Practical implications -Metal shields can be created with ease and great accuracy using RP machines. It takes less time without inflated costs. Models are more accurately and easy to use, with less trauma experienced by the patient during the manufacturing phase. Originality/value -Novel applications, combined with a new process. The research expands the fast-growing field of medical applications of RP technologies. Its practical application will benefit patients on a daily basis.

PurposeThe paper examines whether additive manufacturing can deliver durable injection‐moulding tools – fast, reliable, accurate and economic. Researchers from the Central University of Technology, Free State (CUT), South Africa, are involved in rapid prototyping (RP) applications‐based research, simultaneously using results to support small‐ and medium‐sized enterprises (SMEs) on a national basis – both with contract research and technology transfer[1]. SMEs in South Africa involved in product development, are often hampered by economies of scale. Many new products simply disappear in the product development valley of death, partly due to manufacturing costs and limited product development budgets. RP has been used extensively by Technimark, one of the CUT's industrial partners, to evaluate and verify designs in various design stages. To remain competitive in the global market, Technimark and the CUT often have to apply RP directly as the manufacturing method. The paper discusses the use of RP to support (accelerated) limited production of moulded plastic parts.Design/methodology/approachThe hypothesis is to use additive manufacturing for direct production of injection‐moulding tooling, subject to time, cost and quality constraints.FindingsA case study where both development costs as well as lead‐time forced our industrial partner to trial Alumide as a tooling medium is discussed.Originality/valueThe paper introduces a new rapid tooling material, which may be of cost and time benefit to the product development and plastic injection‐moulding fraternity.

Functional design is closely linked to manufacturing and building. Designers' freedom to express themselves is often limited by the capabilities of craftsmen who have to give physical substance to the designer's ideas. This paper reviews the use of rapid prototyping (RP) to construct complex geometry. Three-dimensional computer aided design data are transferred to a build volume on a 2D layer-by-layer basis. This manufacturing method results in the rapid production of a physical model that can be used to verify designs, check form, fit and functionality, as well as to create a depth perspective. The paper describes a fresh approach into an old industry, i.e. model making. Results proved that models built by conventional methods can be cost-effectively substituted by RP methods without the surface limitations created by cardboard models.

PurposeThe paper reflects on the development of a medical product using rapid prototyping technologies and customer interaction through a quality function deployment (QFD) approach to speed up the process, and to result in customer satisfaction. The purpose of the specific medical product was to develop a device for fixing an Endo‐tracheal (ET) tube in a patient during anaesthesia, as it is common for an ET tube to move and/or become dislodged due to various extraneous reasons. If the tube deviates from the correct position it can cause one or both lungs to collapse, which can be fatal. The paper reviews how the anaesthetist's idea, which was to develop a product that could hold an ET tube in place in a more secure manner than is possible with current technologies, was brought to fruition through customer interaction.Design/methodology/approachUsing an action‐research approach, the design evolved through series of design concepts, which through customer interaction contributed to a total optimized design. Virtual and physical prototypes, together with silicone mouldings were used as part of the customer interaction.FindingsAs with any new product, some functional parts were needed to conduct tests, which in turn would help to prove the product, and hence, the design. Traditionally this meant the manufacturing of a hard tool and proving of the design through trial and error. Hard tooling allows for some small changes to be made, but if the changes are radical a new tool will have to be designed and manufactured.Research limitations/implicationsFollowing a developmental approach through the application of various types/stages of prototyping (such as virtual prototypes), revolutionised this process by simplifying and accelerating the development iteration process – it also developed a new version/paradigm of QFD.Practical implicationsOpposed to traditional forms of QFD where customer inputs are gathered through questionnaires, this case study proved that functional models provide an efficient client‐feedback, through constant involvement in the development process, as well as evaluation of the systematic progress.Originality/valueThe case study shows that experts in other disciplines can become involved in the product development process through the availability of functional prototypes, and builds on previous work to introduce a concept of customer interaction with functional prototypes.