Art, Architecture, Industrial Design

Sculptural objects probably have been fabricated most frequently using stereolithography, but every technology has been used at one time or another as an artistic medium. A major limitation with most technologies is the size of the objects that can be formed, although some creative solutions have been applied. Laminated object manufacturing (LOM) technology has been used to make statues greater than 25 ft tall. The statue of a dolphin shown below was made using a technique similar to LOM and is about 5½ feet long. More recently three dimensional printing (3DP) has enjoyed increasing popularity due to its low material costs and ability to fabricate in color. The selection of a technology is frequently based on the type of aesthetic effect that an artist is trying to achieve, and some artists seem particularly fond of ProMetal for direct metal fabrication. Of course, additive fabrication is also frequently used to make patterns for sculptures which are then cast using the full range of available techniques.

Sculptural form from a ModelMaker pattern.	Sculpture directly fabricated using MultiJet Modeling (MJM)	Pattern for sculpture made using three dimensional printing (3DP).	Final sculpture, cast in bronze and hand finished.
(Courtesy, Bathsheba Grossman Protoshape, Inc.)	(Courtesy, Keith Brown, Fine Art Sculptors and Technology in the UK [FAST])	(Courtesy, Bathsheba Grossman Protoshape, Inc.)	(Courtesy, Bathsheba Grossman Protoshape, Inc.)

Jewelry applications most frequently use Solidscape's ModelMaker™ (MM) inkjet-based technology because it offers high resolution and materials that can be directly cast using the lost wax process. A highly-competitive alternative which has been gaining ground against Solidscape recently is Envisiontec's Perfactory™ system. For about the same price as the Solidscape machine, Envisiontec offers nearly as good resolution combined with much faster build times. These photopolymer-based machines use a deformable mirror device to expose an entire layer at once. Jetted photopolymer systems are also available which closely match jewelry requirements, but generally sell for higher prices and are slower. Stereolithography is also used to make jewelry patterns, and also has been occasionally used for direct fabrication of final pieces.

Dolphin statue fabricated with Tru-Surf (TM), similar to laminated object manufacturing (LOM).	Ring design fabricated using stereolithography.	A delicate jewelry casting pattern made using ModelMaker inkjet technology.	A ring cast from a ModelMaker pattern.
(Courtesy, Gilmore Engineers, Pty. Australia)	(Courtesy, Cadem A.S., Turkey)	(Courtesy, M2 Systems)	(Courtesy, M2 Systems, designed by Peter Indorf, Jeweler, New Haven, CT.)

Architectural models were frequently been made in the past using laminated object manufacturing (LOM), but the process has become much less available. It was an easy technology for architects to relate to since paper models are evocative of the wood and other materials used in manual modeling processes and can also be quite large. Most architectural models today utilize three dimensional printing (3DP) technology. The color capability of the process is especially useful, and it's also helpful for modeling landscapes or industrial process plants, such as refineries. Color can be used to encode particular mechanical or chemical functions or material streams. Another advantage of three dimensional printing is the ability to directly label the surface of the model with text to call attention to specific features or provide explanations. Fused deposition modeling (FDM) is probably the second most popular technology used for architectural models at present, but lacks full color capability. It is possible to change colors, but with some interruption and difficulty. One advantage of FDM is that the models are quite rugged compared to those made by 3DP. Architectural models frequently must travel or be set up in multiple locations so this is not a minor benefit. Selective laser sintering is also used, but much less frequently.

Piping model of a chemical plant fabricated by color three dimensional printing (3DP). (Courtesy, Z Corp.)

New service bureaus have been established and several existing service bureaus have made new divisions specifically to serve the architectural modeling market. Nearly all use either FDM or 3DP technology. More than twenty service bureaus now claim expertise in architectural applications.

A large model made with three dimensional printing (3DP).	Complex structure modeled with three dimensional printing (3DP)	Internal features can be modeled simultaneously with external ones.
(Courtesy, Z Corporation)	(Courtesy, Laser Graphic Manufacturing designed by ALM Architects, Inc.)	(Courtesy, Z Corporation)

Rapid prototyping can be used to easily make models at multiple scales.
(Courtesy, Laser Graphic Manufacturing)

Industrial design models are increasingly being made with rapid prototyping, although the desired detail, resolution and finish are as yet beyond the capability of any RP technology. One of the major driving forces has been the introduction of full color capability in three dimensional printing (3DP). A lot of industrial design work is also done using selective laser sintering (SLS), fused deposition modeling (FDM) and stereolithography. Methods that produce models in something close to a real plastic seem to be preferred over photopolymer-based technologies, but photopolymers can be finished to provide a surprisingly realistic appearance. Designers are learning that being able to quickly see and iterate a design even though a model may not be perfect in every detail is a good compromise.

Painted stereolithography part for industrial design study. (Courtesy, Accelerated Technologies, Inc.)