1

CAD
Computer-aided design (CAD), also known as computer-aided design and drafting (CADD),
is the use of computer technology for the process of design and design-documentation. Computer
Aided Drafting describes the process of drafting with a computer. CADD software, or
environments, provides the user with input-tools for the purpose of streamlining design
processes; drafting, documentation, and manufacturing processes. CADD output is often in the
form of electronic files for print or machining operations. The development of CADD-based
software is in direct correlation with the processes it seeks to economize; industry-based
software (construction, manufacturing, etc.) typically uses vector-based (linear) environments
whereas graphic-based software utilizes raster-based (pixilated) environments.

CADD environments often involve more than just shapes. As in the manual drafting of technical
and engineering drawings, the output of CAD must convey information, such as materials,
processes, dimensions, and tolerances, according to application-specific conventions.

CAD may be used to design curves and figures in (2D) space; or curves, surfaces, and solids in
(3D) objects. CAD is an important industrial art extensively used in many applications, including
automotive, shipbuilding, and aerospace industries, industrial and architectural design, and many
more. Current computer-aided design software packages range from 2D vector-based drafting
systems to 3D solid and surface modelers. Modern CAD packages can also frequently allow
rotations in three dimensions, allowing viewing of a designed object from any desired angle,
even from the inside looking out. Some CAD software is capable of dynamic mathematic
modeling, in which case it may be marketed as CADD — computer-aided design and
drafting.CAD is used in the design of tools and machinery and in the drafting and design of all
types of buildings, from small residential types (houses) to the largest commercial and industrial
structures (hospitals and factories).

CAD is mainly used for detailed engineering of 3D models and/or 2D drawings of physical
components, but it is also used throughout the engineering process from conceptual design and
layout of products, through strength and dynamic analysis of assemblies to definition of
manufacturing methods of components. It can also be used to design objects.

CAD has become an especially important technology within the scope of computer aided
technologies, with benefits such as lower product development costs and a greatly shortened
design cycle. CAD enables designers to lay out and develop work on screen, print it out and save
it for future editing, saving time on their drawings.

CAM
Computer-aided manufacturing (CAM) is the use of computer software to control machine
tools and related machinery in the manufacturing of work pieces. This is not the only definition
for CAM, but it is the most common; CAM may also refer to the use of a computer to assist in all
operations of a manufacturing plant, including planning, management, transportation and
storage. Its primary purpose is to create a faster production process and components and tooling
1

with more precise dimensions and material consistency, which in some cases, uses only the
required amount of raw material (thus minimizing waste), while simultaneously reducing energy
consumption.

CAM is a subsequent computer-aided process after computer-aided design (CAD) and

sometimes computer-aided engineering (CAE), as the model generated in CAD and verified in
CAE can be input into CAM software, which then controls the machine tool.

Traditionally, CAM has been considered as a numerical control (NC) programming tool, wherein
two-dimensional (2-D) or three-dimensional (3-D) models of components generated in CAD
software are used to generate G-code to drive computer numerically controlled (CNC) machine
tools. Simple designs such as bolt circles or basic contours do not necessitate importing a CAD
file.

As with other “Computer-Aided” technologies, CAM does not eliminate the need for skilled
professionals such as manufacturing engineers, NC programmers, or machinists. CAM, in fact,
leverages both the value of the most skilled manufacturing professionals through advanced
productivity tools, while building the skills of new professionals through visualization,
simulation and optimization tools.

Conventional Design Methods

Limitations and Errors
The early design methods were very time consuming and a lot of effort was required to design even a
simple object. We have to spend hours on the table and a lot much calculation was required manually to
obtain the desire component or any other design. Also a lot of paper and pencil work was required. The
drawing blue prints are also very much costly. (Blueprints are exact copies of mechanical or other types
of drawings and employ a language of their own. It is a form of sign language or shorthand that uses
lines,  graphic  symbols,  dimensions,  and  notations to  accurately  describe the form size,  kind  of
material, finish, and construction of an object).

The paper drawings were only limited to 2D. If it was supposed to work on a 3D model, then the
work got very much complex or complicated. Also if the desired design of the component or part
consisted of curved profiles, then a lot of mathematical calculations were likely to involve. In other
words, our designing ideas and thoughts were limited to get visualized.

If you are working with the part or design manually, then the part’s tolerances and accuracy is
limited by the handling of the machine. So when you go the manufacturing, then you are limited by the
skills of your labor which has its own limitation. Therefore when you are controlling the feed and other
machining parameters manually, i.e. by your own hand, you can achieve a high accuracy and the
machining or the manufacturing operation is then, not very much précised.
1

How CAD CAM Helps In Design

1. Increase the precision of drawings.
2. Reduce the man hours involved with design.
3. Reduce the cost of drawing blue prints.

We can now work in 3D with lines, arcs, splines, and many types of surfaces. Computer assisted design
involves a lot of the basic geometric principles that you learned in high school math (and you said you'd
never need it!). Today, designing CAD drawings requires you to know how to calculate angles, do some
basic math, and, most importantly, think logically. Through CAD, you can translate your concept design
to product design. The CAD technology has explored the limitations of design, giving you an ultimate
freedom of design. Now you can handle complexity and other parameters that were virtually impossible
with earlier design techniques. It has also allowed you to design and think innovatively.

The most important feature of CAD is the RP means, rapid prototyping. (Rapid prototyping is
the automatic construction of physical objects using additive manufacturing technology. manufacturing
for 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 successive layers
until the model is complete). It allows you to study and examine the physical aspects of you design
without going through a very long process of manufacturing. Using CAD, you can also check and analyze
your design virtually which also saves the cost of prototyping and test manufacturing. The highly curved
aerodynamic curved profiles are easily design by the help of CAD.

CAM software systems promote many product features, like high-speed machining
technologies, multi-axis machining, and precise machining. There are many simulation (Simulation is the
process of designing a model of a real system and conducting experiments with this model for the
purpose either of understanding the behavior of system or of evaluation various strategies within the
limits imposed by a criterion or set of criteria for the operation of the system) techniques available now,
through which an analysis can be performed like under actual condition. The CAM has also made a way
to precision and accurate machining and manufacturing by the ability to work with multi axis
simultaneously which has also provided a path to machine very odd and complex 3D geometries.

Introduction
STS (SPEL TECHNOLOGY SUPPORT (Pvt) Ltd.) belongs to SPEL Group of Companies. For more
than 25 years, SPEL has been working for the engineering industry and producing quality molds
and injection molded products. SPEL has regularly upgraded its manufacturing facilities and
implementing the latest advances in technology.

STS was working as a division of SPEL since 1998. On 2nd January 2009, STS was converted into
a corporate status.
1

STS works closely with its customers and turn their concepts into finished components and
parts. We have foreign trained, highly qualified and experienced staff to ensure quality service
to our customers.

STS Staff is committed to promote the local industry by using their expertise in the field.

STS specializes in providing quality high speed machining solutions to the entire engineering
industry. These services are provided using latest CNC machines and related high end software
for which we have exclusive agencies of world’s renowned companies.

We have the expertise of professional engineers and trained marketing staff who are well
versed in translating client’s needs into applicable engineering solutions resulting in enhanced
profitability and productivity. Our qualified teams of technical experts also provide training and
after sales support on the shop floor level to ensure seamless operation of high end setup
including CNC Setup training and CAD/CAM initiation classes as well as reverse engineering
services for parts.

STS believes in “TOTAL CUSTOMER SATISFACTION”. We are at present catering to a large

customer base comprising both public and private sector enterprises include Automotive,
Surgical, Sports, Sheet Metal, Footwear, Defense and Aerospace sectors, proving the trust and
confidence our clients repose in us.

We also offer TURNKEY solutions to help you win in the market.

PRODUCTION
Their products are:

1. Steering

2. Front Grills

3. Door Trims

4. Back Light

5. Garnishes

6. Rims

7. Steering Knobs

8. Steering Column
1

9. Water Gallons 20 Kg

10. Disposable Cups and plastic Plates

11. Plastic Cans

REVERSE ENGINEERING
Reverse engineering is the process of discovering the technological principles of a device,
object or system through analysis of its structure, function and operation. It often involves taking
something (e.g., a mechanical device, electronic component, or software program) apart and
analyzing its workings in detail to be used in maintenance, or to try to make a new device or
program that does the same thing without using or simply duplicating (without understanding)
any part of the original.

Reverse engineering has its origins in the analysis of hardware for commercial or military
advantage. The purpose is to deduce design decisions from end products with little or no
additional knowledge about the procedures involved in the original production. The same
techniques are subsequently being researched for application to legacy software systems, not for
industrial or defense ends, but rather to replace incorrect, incomplete, or otherwise unavailable
documentation.

Reasons for reverse engineering:

 Interoperability.
 Lost documentation: Reverse engineering often is done because the documentation of a
particular device has been lost (or was never written), and the person who built it is no
longer available. Integrated circuits often seem to have been designed on obsolete,
proprietary systems, which means that the only way to incorporate the functionality into
new technology is to reverse-engineer the existing chip and then re-design it.
 Product analysis. To examine how a product works, what components it consists of,
estimate costs, and identify potential patent infringement.
 Digital update/correction. To update the digital version (e.g. CAD model) of an object to
match an "as-built" condition.
 Security auditing.
 Acquiring sensitive data by disassembling and analyzing the design of a system
component
 Military or commercial espionage. Learning about an enemy's or competitor's latest
research by stealing or capturing a prototype and dismantling it.
 Removal of copy protection, circumvention of access restrictions.
1

 Creation of unlicensed/unapproved duplicates.

 Materials harvesting, sorting, or scrapping.
 Academic/learning purposes.
 Curiosity.
 Competitive technical intelligence (understand what your competitor is actually doing
versus what they say they are doing).
 Learning: learn from others' mistakes. Do not make the same mistakes that others have
already made and subsequently corrected.

Reverse engineering of machines

As computer-aided design (CAD) has become more popular, reverse engineering has become a
viable method to create a 3D virtual model of an existing physical part for use in 3D CAD,
CAM, CAE or other software. The reverse-engineering process involves measuring an object and
then reconstructing it as a 3D model. The physical object can be measured using 3D scanning
technologies like CMMs, laser scanners, structured light digitizers or Industrial CT Scanning
(computed tomography). The measured data alone, usually represented as a point cloud, lacks
topological information and is therefore often processed and modeled into a more usable format
such as a triangular-faced mesh, a set of NURBS surfaces or a CAD model.

Reverse engineering is also used by businesses to bring existing physical geometry into digital
product development environments, to make a digital 3D record of their own products or to
assess competitors' products. It is used to analyse, for instance, how a product works, what it
does, and what components it consists of, estimate costs, and identify potential patent
infringement, etc.

Value engineering is a related activity also used by businesses. It involves de-constructing and
analyzing products, but the objective is to find opportunities for cost cutting.

G CODES AND M CODES

G-code is the common name for the most widely used numerical control (NC) programming
language, which has many implementations. This general sense of the term, referring to the
language overall (using the mass sense of "code"), is imprecise, because it comes metonymically
from the literal sense of the term, referring to one letter address among many in the language (G
address, for preparatory commands) and to the specific codes (count sense) that can be formed
with it (for example, G00, G01, G28). In fact, every letter of the English alphabet is used
somewhere in the language, although some letters' use is less common. Nevertheless, the general
sense of the term is indelibly established as the common name of the language.

The first implementation of numerical control was developed at the MIT Servomechanisms
Laboratory in the early 1950s. In the decades since, many implementations have been developed
by many (commercial and noncommercial) organizations. G-code has often been used in these
1

implementations. Extensions and variations have been added independently by control

manufacturers and machine tool manufacturers, and operators of a specific controller must be
aware of differences of each manufacturer's product.

One standardized version of G-code, known as BCL, is used only on very few machines.

Some CNC machine manufacturers attempted to overcome compatibility difficulties by

standardizing on machine tool controllers built by Fanuc. This semi standardization can be
compared to other instances of market dominance, such as with IBM, Intel, or Microsoft. Pros
and cons exist, and a wide variety of alternatives are available.

G-code began as a limited type of language that lacked constructs such as loops, conditional
operators, and programmer-declared variables with natural-word-including names (or the
expressions in which to use them). It was thus unable to encode logic; it was essentially just a
way to "connect the dots" where many of the dots' locations were figured out longhand by the
programmer. The latest implementations of G-code include such constructs, creating a language
somewhat closer to a high-level programming language. The more a programmer can tell the
machine what end result is desired, and leave the intermediate calculations to the machine, the
more s/he uses the machine's computational power to full advantage.

G Codes
G commands often tell the control what kind of motion is wanted (e.g., rapid positioning, linear
feed, circular feed, fixed cycle) or what offset value to use.

M Codes
Action code, auxiliary command; descriptions vary. Many M-codes call for machine functions,
which is why people often say that the "M" stands for "machine", although it was not intended
to.

SURFACE MODELING
3D Printing

3D printing is a form of additive manufacturing technology where a three dimensional object is

created by laying down successive layers of material. 3D printers are generally faster, more
affordable and easier to use than other additive manufacturing technologies. 3D printers offer
product developers the ability to print parts and assemblies made of several materials with
different mechanical and physical properties in a single build process. Advanced 3D printing
technologies yield models that closely emulate the look, feel and functionality of product
prototypes.

A 3D printer works by taking a 3D computer file and using and making a series of cross-
sectional slices. Each slice is then printed one on top of the other to create the 3D object.
1

Since 2003 there has been large growth in the sale of 3D printers. Additionally, the cost of 3D
printers has declined. The technology also finds use in the jewellery, footwear, industrial design,
architecture, engineering and construction (AEC), automotive, aerospace, dental and medical
industries.

3D Scanner

A 3D scanner is a device that analyzes a real-world object or environment to collect data on its
shape and possibly its appearance (i.e. color). The collected data can then be used to construct
digital, three dimensional models useful for a wide variety of applications. These devices are
used extensively by the entertainment industry in the production of movies and video games.
Other common applications of this technology include industrial design, orthotics and
prosthetics, reverse engineering and prototyping, quality control/inspection and documentation
of cultural artifacts.

Many different technologies can be used to build these 3D scanning devices; each technology
comes with its own limitations, advantages and costs. It should be remembered that many
limitations in the kind of objects that can be digitized are still present: for example optical
technologies encounter many difficulties with shiny, mirroring or transparent objects.

There are however methods for scanning shiny objects, such as covering them with a thin layer
of white powder that will help more light photons to reflect back to the scanner. Laser scanners
can send trillions of light photons toward an object and only receive a small percentage of those
photons back via the optics that they use. The reflectivity of an object is based upon the object's
color or terrestrial albedo. A white surface will reflect lots of light and a black surface will reflect
only a small amount of light. Transparent objects such as glass will only refract the light and give
false three dimensional information.

Surface Modeling

Delcam has strong capabilities of surface modeling as compared to other CAD softwares.

CAE ANALYSIS
Computer-aided engineering (often referred to as CAE) is the use of information technology to
support engineers in tasks such as analysis, simulation, design, manufacture, planning, diagnosis,
and repair.

Software tools that have been developed to support these activities are considered CAE tools.
CAE tools are being used, for example, to analyze the robustness and performance of
components and assemblies. The term encompasses simulation, validation, and optimization of
products and manufacturing tools. In the future, CAE systems will be major providers of
information to help support design teams in decision making.

Engineers in fields from Aerospace, Automotive to Bio-Medical use CAE in tasks such as
1

analysis, simulation, design, manufacture, planning, diagnosis and repair. It encompasses

simulation, validation and optimization of products and manufacturing tools.

Among the CAE areas covered include:

1.  Stress analysis on components and assemblies

     using FEA (Finite Element Analysis);
2.  Thermal and fluid flow analysis Computational fluid dynamics (CFD).
3.  Kinematics;
4.  Mechanical event simulation (MES).
5.  Analysis tools for process simulation for operations
     such as casting, molding, and die press forming.
6.  Optimization of the product or process.

CNC MACHINE
Numerical Control
Numerical control (NC) refers to the automation of machine tools that are operated by
abstractly programmed commands encoded on a storage medium, as opposed to manually
controlled via hand wheels or levers, or mechanically automated via cams alone. The first NC
machines were built in the 1940s and '50s, based on existing tools that were modified with
motors that moved the controls to follow points fed into the system on punched tape. These early
servomechanisms were rapidly augmented with analog and digital computers, creating the
modern computer numerical controlled (CNC) machine tools that have revolutionized the
manufacturing process.

In modern CNC systems, end-to-end component design is highly automated using computer-
aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs
produce a computer file that is interpreted to extract the commands needed to operate a particular
machine via a postprocessor, and then loaded into the CNC machines for production. Since any
particular component might require the use of a number of different tools-drills, saws, etc.-
modern machines often combine multiple tools into a single "cell". In other cases, a number of
different machines are used with an external controller and human or robotic operators that move
the component from machine to machine. In either case, the complex series of steps needed to
produce any part is highly automated and produces a part that closely matches the original CAD
design.

CNC
Computer numerical control (CNC) machines are automated milling machines that make
industrial components without human assistance. This is possible because CNC machines are fed
a series of instructions that are delivered to an internal computer controller. These instructions
are in the form of codes that belong to the numerical control programming language.
1

The code used to program CNC machines is generically called G-code. However, G-code
instructions are only part of the programming language. Specifically, G-codes give CNC
machines the coordinates from which to hold and engage the machining tool in order to cut and
shape metal to certain specifications. The entire series of codes used to operate CNC machines
also include M-codes and T-Codes, which manage the CNC machine and drill tool, respectively.
Tooling speed and feed controls are dictated by S-Codes and F-Codes, while X, Y, and Z-codes
determine absolute position.

CMM
A coordinate measuring machine (CMM) is a device for measuring the physical geometrical
characteristics of an object. This machine may be manually controlled by an operator or it may be
computer controlled. Measurements are defined by a probe attached to the third moving axis of this
machine. Probes may be mechanical, optical, laser, or white light, among others.

The typical "bridge" CMM is composed of three axes, an X, Y and Z. These axes are orthogonal
to each other in a typical three dimensional coordinate system. Each axis has a scale system that
indicates the location of that axis. The machine will read the input from the touch probe, as
directed by the operator or programmer. The machine then uses the X,Y,Z coordinates of each of
these points to determine size and position. Typical precision of a coordinate measuring machine
is measured in Microns, or Micrometers, which is 1/1,000,000 of a meter.

A coordinate measuring machine (CMM) is also a device used in manufacturing and assembly
processes to test a part or assembly against the design intent. By precisely recording the X, Y,
and Z coordinates of the target, points are generated which can then be analyzed via regression
algorithms for the construction of features. These points are collected by using a probe that is
positioned manually by an operator or automatically via Direct Computer Control (DCC). DCC
CMMs can be programmed to repeatedly measure identical parts, thus a CMM is a specialized
form of industrial robot.

DEL CAM
Delcam is one of the world's leading suppliers of advanced CAD/CAM software product
development solutions for the manufacturing industry. The company has grown steadily since
being founded formally in 1977, after initial development work at Cambridge University, UK. It
1

is now a global developer of product design and manufacturing software, with subsidiaries in
North America, Europe and Asia. Power MILL - Specialist NC CAM software for the
manufacture of the complex shapes
Feature CAM - Automated machining for parts on mills, lathes and wire EDM
Part Maker - Applies a visual programming approach to make CNC programming quicker and
easier
Power SHAPE - CAD design and modeling software for total design solutions
Power INSPECT - Inspection software (OMV, Manual CMMs, CNC CMM's, Inspection Arms,
Optical MMs, Laser Trackers and Line Laser Probes)
Delcam CRISPIN - Sole Engineering for the footwear Industry
Copy CAD - Reverse Engineering software
Exchange - The CAD translation solution
Art CAM - Provides a unique CAD modeling and CNC CAM machining solution
Art CAM Insignia - The easiest professional CNC routing and engraving software
Art CAM Insignia E - Insignia E is an entry level 2D routing package
Art CAM Jewel Smith - Software to design and manufacture jewellery quickly and easily
Mill Wizard - Create real 3D objects from your favorite 3D modeling program using the Art C
AM Mill Wizard software
Dental Solutions - CAD modeling and cam machining solutions for the dental industry
Orthotics Solutions - CAD CAM software for the manufacturing needs of bespoke orthotics and
orthopedic footwear
Orthopedic Solutions - CAD CAM software tailor made for the Orthopedic Industry.
PS-Team - An EPM, project management and program management solution.

Design for manufacturability for CNC machining

Design for manufacturability (DFM) describes the process of designing or engineering a product in order
to facilitate the manufacturing process in order to reduce its manufacturing costs. DFM will allow
potential problems to be fixed in the design phase which is the least expensive place to address them.
The design of the component can have an enormous effect on the cost of manufacturing. Other factors
may affect the manufacturability such as the type of raw material, the form of the raw material,
dimensional tolerances, and secondary processing such as finishing.

Material Type

The most easily machined types of metals include aluminum, brass, magnesium, and softer
metals. As materials get harder, denser and stronger, such as steel, stainless steel, titanium, and
exotic alloys, they become much harder to machine and take much longer, thus being less
manufacturable. Most types of plastic are easy to machine, although additions of fiberglass or
carbon fiber can reduce the machinability. Plastics that are particularly soft and gummy may
have machinability problems of their own.

Material Form
1

Metals come in all forms. In the case of aluminum as an example, bar stock and plate are the two
most common forms from which machined parts are made. The size and shape of the component
may determine which form of material must be used. It is common for engineering drawings to
specify one form over the other. Bar stock is generally close to 1/2 of the cost of plate on a per
pound basis. So although the material form isn't directly related to the geometry of the
component, cost can be removed at the design stage by specifying the least expensive form of the
material.

Dimensional Tolerances

A significant contributing factor to the cost of a machined component is the geometric tolerance
to which the features must be made. The higher the tolerance required, the more expensive the
component will be to machine. When designing, specify the lowest tolerance that will serve the
function of the component. Tolerances must be specified on a feature by feature basis. There are
creative ways to engineer components with lower tolerances that still perform as well as ones
with higher tolerances.

Design and shape

As machining is a subtractive process, the time to remove the material is a major factor in
determining the machining cost. The volume and shape of the material to be removed as well as
how fast the tools can be fed will determine the machining time. When using milling cutters, the
strength and stiffness of the tool which is determined in part by the length to diameter ratio of the
tool will play the largest role in determining that speed. The shorter the tool is relative to its
diameter the faster it can be fed through the material. A ratio of 3:1 (L:D) or under is optimum. If
that ratio cannot be achieved, a solution like this depicted here can be used. For holes, the length
to diameter ratio of the tools are less critical, but should still be kept under 10:1.

There are many other types of features which are more or less expensive to machine. Generally
chamfers cost less to machine than radii on outer horizontal edges. Undercuts are more
expensive to machine. Features that require smaller tools, regardless of L:D ratio, are more
expensive.

Multi axis machining

Multi axis machining is a manufacturing process, where computer numerically controlled tools
that move in 4 or more ways are used to manufacture parts out of metal or other materials by
milling away excess material, by water jet cutting or by laser cutting. Typical CNC tools support
translation in 3 axes; multi axis machines also support rotation around one or multiple axes.

There are now many CAM (computer aided manufacturing) software systems available to
support multi axis machining including software that can automatically convert 3-axes toolpaths
into 5-axes toolpaths.
1

Multi axis machines offer several improvements over other CNC tools at the cost of increased
complexity and price of the machine:

 Amount of work is reduced, if the piece would otherwise have to be turned manually during the
machining.
 Better surface finish can be obtained by moving the tool tangentially about the surface.
 More complex parts can be manufactured, particularly parts with curved holes.

Number of axes for multi axis machines varies from 4 to 9. Each axis of movement is implemented either
by moving the table (into which the work piece is attached), or by moving the tool. The actual
configuration of axes varies; therefore machines with the same number of axes can differ in the
movements that can be performed.

Rapid prototyping
Rapid prototyping is the automatic construction of physical objects using additive manufacturing
technology. The first techniques for rapid prototyping became available in the late 1980s and were used
to produce models and prototype parts. Today, they are used for a much wider range of applications
and are even used to manufacture production-quality parts in relatively small numbers. Some sculptors
use the technology to produce complex shapes for fine arts exhibitions.

manufacturing for 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 successive layers until the model is complete. It is a WYSIWYG process where the
virtual model and the physical model are almost identical.

With additive manufacturing, 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. Smaller 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.

Some solid freeform fabrication techniques use two materials in the course of constructing parts.
The first material is the part material and the second is the support material (to support
1

overhanging features during construction). The support material is later removed by heat or
dissolved away with a solvent or water.

Traditional injection molding can be less expensive for manufacturing polymer products in high
quantities, but additive fabrication can be faster and less expensive when producing relatively
small quantities of parts. 3D printers give designers and concept development teams the ability to
produce parts and concept models using a desktop size printer.

Rapid prototyping is now entering the field of rapid manufacturing and it is believed by many
experts that this is a "next level" technology.

Selective laser sintering

Selective laser sintering (SLS) is an additive manufacturing technique that uses a high power
laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal (Direct Metal
Laser Sintering), ceramic, or glass powders into a mass that has a desired 3-dimensional shape.
The laser selectively fuses powdered material by scanning cross-sections generated from a 3-D
digital description of the part (for example from a CAD file or scan data) on the surface of a
powder bed. After each cross-section is scanned, the powder bed is lowered by one layer
thickness, a new layer of material is applied on top, and the process is repeated until the part is
completed.

Compared to other methods of additive manufacturing, SLS can produce parts from a relatively
wide range of commercially available powder materials. These include polymers such as nylon,
(neat, glass-filled or with other fillers) or polystyrene, metals including steel, titanium, alloy
mixtures, and composites and green sand. The physical process can be full melting, partial
melting, or liquid-phase sintering. And, depending on the material, up to 100% density can be
achieved with material properties comparable to those from conventional manufacturing
methods. In many cases large numbers of parts can be packed within the powder bed, allowing
very high productivity.

SLS is performed by machines called SLS systems. SLS technology is in wide use around the
world due to its ability to easily make very complex geometries directly from digital CAD data.
While it began as a way to build prototype parts early in the design cycle, it is increasingly being
used in limited-run manufacturing to produce end-use parts. One less expected and rapidly
growing application of SLS is its use in art.

SLS was developed and patented by Dr. Carl Deckard at the University of Texas at Austin in the
mid-1980s, under sponsorship of DARPA. A similar process was patented without being
commercialized by R.F. Householder in 1979.
1

Unlike some other additive manufacturing processes, such as Stereolithography (SLA) and Fused
Deposition Modeling (FDM), SLS does not require support structures due to the fact that the part
being constructed is surrounded by unsintered powder at all times.