The RAPID 2013 Conference & Exposition Directory - Society of ...

OffiCiaL EvEnT DirECTOry
The Third Dimension.
Discover more than you know.
JUNE 10-13, 2013
David L. Lawrence
Convention Center
Pittsburgh, Pennsylvania
sme.org/rapid
Presented by
Published by
including
Photos courtesy of Morris Tech (left, right) C.ideas (middle left), and EOS (middle right)

dedicated to
advancing additive
manufacturing
get connected at booth 902
namii.org
driven by

CONTENTS
Welcome ............................................................1
General Information..........................................2
SME Fact Sheet .................................................5
SME Membership Application ........................7
Special Programs & Activities ......................10
Advisors ............................................................14
Careers in Technology ...................................18
Sponsors & Supporters..................................20
Event-At-A-Glance..........................................24
Workshops & Tours ........................................26
Contemporary Art Gallery ..............................28
Keynote Presentations....................... ............30
Networking Receptions .................................32
Conference Details .........................................34
Floor Plan..........................................................56
Exhibitor Listing—Alphabetical ....................57
Additive Manufacturing: Going Mainstream .. 64
Exhibitor Listing–Products ............................70
Ad Index............................................................72
WElCOmE
Improve Your Manufacturing!
Additive Manufacturing, 3D Printing, 3D Scanning, Digital Data, RAPID Prototyping and
NAMII are resources and tools to assist in manufacturing better products. If you don’t
take advantage of these tools and resources, your manufacturing remains stagnant
and your company falls behind.
The basics of manufacturing can get lost in all the hype and publicity that these
technologies are receiving. Investors, do-it-yourselfers, designers and artists are
searching for how these technologies can fit their needs. Manufacturers, on the other
hand, are implementing the technology to improve part production and build quality,
and speed parts into market, while reducing the expense.
RAPID 2013 Conference Sessions continue to provide information and opportunities to
hear about the latest applications. There are new sessions on Innovative Applications
and Product Design, expanded presentations addressing Direct Write Printed
Materials and more on Additive Applications and AM Research. The conference
continues to provide applications for Medical, Transportation and Casting.
The RAPID Exposition is the business of additive manufacturing and 3D scanning. The
equipment, services and people are resources for your workplace. Explore and talk
to all the exhibitors to enhance your knowledge of what can be accomplished. Learn
what they have to offer your manufacturing process and then vote on the company that
deserves “Best in Show Award.” Voting closes at the end of the networking reception
on Tuesday. Enjoy this opportunity to meet and make friends.
The Rapid Technologies & Additive Manufacturing (RTAM) Community invites you to
become an SME member and stay current with this growing technology. This year
SME welcomes the National Additive Manufacturing Innovation Institute (NAMII) to
the event. The organization’s singular focus is to accelerate additive manufacturing
technologies to the US manufacturing sector and increase domestic manufacturing
competitiveness. Tuesday’s keynote will reinforce this while Wednesday’s will
overview the state of the industry. The Conference Kick-Off on Monday will provide a
future look at technology and review some of the past AM innovations that have built
the foundation for where we are today.
Welcome to RAPID 2013! Enjoy your time in Pittsburgh!
Sincerely,
Dennis S. Bray, PhD, FSME
President
Society of Manufacturing Engineers
Greg Morris
Strategy & Business Development,
Additive Technologies
GE AviationText
6/2013 – RAPID 1

GENERAL INFORMATION
Exposition and Conference Registration
The on-site exposition registration fee for RAPID 2013 is
$60. Admission is free to SME members with a current SME
membership card or holders of an exhibitor show ticket. On-site
fees for the conference can be found on the registration form in
the registration area.
No one under 18 years of age admitted. Minors, 16 years of age
and above, may attend if dressed appropriately and accompanied
by a parent or guardian.
Conference/Speaker Office
The RAPID Conference/Speaker Office is located in Room 309
and can be reached at 412.325.6012. Advisors and Speakers are
required to register there.
Media Information
Press badges will be administered in the RAPID Press Room
and will be limited to press with valid credentials. The Press
Room is located near registration at the entrance of the exhibit
hall. Please bring a form of ID and business card, copy of a
recent publication, or a copy of a recent article with your byline
for verification. Advertising or sales representatives will not
be granted press badges. SME staff will assist members of the
media with registration and media kits in the Press Room: Hall B
Entrance. The Press Room can be reached at 412.326.6011.
Recording equipment (audio or video) is permitted for news coverage
only and should be used only to film B-roll and interviews.
Recording devices are NOT allowed to record presentations,
lectures or conference sessions without written permission from
the presenter and the SME Event Manager or PR Representative.
design today…
…build tomorrow
Unlock the potential of Additive Manufacturing
Renishaw’s laser melting system is a pioneering process capable
of producing fully dense metal parts direct from 3D CAD.
From tooling inserts featuring conformal cooling, to lightweight
structures for aerospace and high technology applications,
laser melting gives designers more freedom, resulting in
structures and shapes that would otherwise be constrained by
conventional processes or the tooling requirements of volume
production. It is also complementary to conventional machining
Renishaw Inc Hoffman Estates, IL
www.renishaw.com/additive
technologies, and directly contributes to reduced lead
times, tooling costs and material waste.
■ Shorten development time—be first to market
■ Reduce waste and cost—build only what you need
■ Increase design freedom—create complex structures
and hidden features
See us at RAPID
BOOTH #411
2 sme.org/rapid

cmyk
Event Hours
Exposition
Tuesday, June 11
8 am–7 pm
Wednesday, June 12
8 am–3 pm
Conference
Monday, June 10
9 am–1:30 pm Workshops
2:30–5:30 pm Conference Kick-Off
Tuesday, June 11
8 am–5 pm
Wednesday, June 12
8 am–3:30 pm
Registration
Monday, June 10
8 am–5 pm
Tuesday, June 11
7 am–6 pm
Wednesday, June 12
7 am–2 pm
Networking Receptions
Monday, June 10
5:30–10 pm at the Andy Warhol Museum
Tuesday, June 11
5:30–7 pm on the Show Floor
Tours
Tuesday, June 11
3:30–6 pm at Bally Design
Thursday, June 13
8:30 am–12:30 pm at ExOne & threeRivers 3D
or HERL-VA Pittsburgh & TechShop Pittsburgh
Visitors Center
Visit the Greater Pittsburgh Convention & Visitors Bureau at
www.visitpittsburgh.com or call 800.359.0758 to find information
on area dining, shopping and attractions. There will be a Visit
Pittsburgh booth outside the exhibit hall as well. It will be staffed
with individuals who can make recommendations on restaurants
and attractions as well as provide brochures, menus, maps, etc.
Special Offer for RAPID Attendees!
Enjoy the ‘Burgh and save money too! Present your RAPID badge
or visiting media credentials at participating local establishments
and take advantage of special offers while you’re in Pittsburgh.
See the Visit Pittsburgh website or booth for details on
participating establishments.
SME Resource Center Location
(Booth #913)
Visit the SME Resource Center, Booth 913, during the show to:
• Connect with local SME/RTAM members and share
manufacturing experiences, problems and solutions
• Learn about the resources available to you with an SME
membership
• Pick up the latest copy of Manufacturing Engineering
magazine
• Learn about Manufacturing Engineering’s Industry Yearbook
Series featuring:
- Medical Manufacturing
- Aerospace & Defense Manufacturing
- Energy
- Motorized Vehicle Manufacturing
If you are not an SME member, now is the perfect time to JOIN—
the information and networking that is available to increase your
knowledge and effectiveness is second to none. You can’t find
a better return on your investment. Meet, Know, Grow with SME
Membership. Visit www.sme.org/join to learn more.
Also learn more about the SME Education Foundation’s mission,
which is to prepare the next generation of manufacturing
engineers and technologists through outreach programs to enrich
students to study Science, Technology, Engineering and Mathematics
(STEM) as well as Computer Integrated Manufacturing
(CIM) education. To learn more, visit www.sme.org/foundation.
6/2013 – RAPID 3

GENERAL INFORMATION
Lost Badges
Lost show badges may be claimed or reprinted at the registration
counter.
Lost & Found
Inquire about lost items at the RAPID Registration Desk.
Emergencies and Security
In the event of a medical emergency, dial 911 from any available
phone. The Convention Center’s Security Office can be reached
at 412.325.6193.
Transportation
SME has negotiated a group discount for airport transfers to/from
the Omni William Penn (or other Downtown Pittsburgh hotels).
To receive the discount, reservations must be made online in
advance at www.supershuttle.com using Group Code RAPID or
by calling 1.800.Blue.Van (258.3826) and mentionig Group Code:
RAPID. Options include:
• SuperShuttle (shared ride van service): $24 one way,
per person
(Rate does not include fuel surcharge or gratuity at
customer discretion)
• ExecuCar (luxury private sedan, seats up to four
passengers): $63 one way
(Rate does not include gratuity at customer discretion)
Tax Deduction
An income tax deduction may be allowed for expenses incurred
for education, including registration fees, travel, lodging, and
meals, primarily for the purpose of maintaining or improving skills
in employment or other trade or business pursuant to Treas. Reg.
§ 1.162-5. Contact your tax consultant for additional details.
Special Requirements
SME is committed to providing reasonable
accommodation to disabled persons who require
such accommodation in order to fully participate in
SME-sponsored events. For details, contact
or visit the RAPID registration counter.
Program Changes
SME reserves the right to amend this program. In the event of a
cancellation, SME is not responsible for incidental costs incurred
by registrants. It is recommended that refundable airline tickets
be purchased.
Photography/Filming Policy
No videotape, motion picture film, or other type of camera is
allowed in the exposition area except those belonging to news
media or technical press that have been approved in advance by
a RAPID Public Relations Representative.
Solicitation Policy
Show exhibitors, in their booths, are the only individuals who
may distribute or display printed material or products. Any other
solicitation is prohibited.
Image courtesy Andrew Werby
4 sme.org/rapid

SME FACT SHEET
Membership
Chapters and Communities
Local chapters and technical communities
allow members to connect, interact, and
exchange ideas and information from one
peer to another.
• Local chapters help build a member
network in your own backyard, meet
potential customers, partners and
employers, and gain leadership
opportunities.
• Technical Communities connect
manufacturing practitioners in specific
disciplines to solve technical and
business challenges.
Events
SME’s industry-leading events provide
hands-on experiences, in-depth technical
sessions and progressive ideas for
integrated solutions to manufacturing
challenges.
Expositions & Conferences
• AeroDef Manufacturing
• Composites Manufacturing Conference
• Mfg4 — Manufacturing 4 the Future
• EASTEC®
• HOUSTEX®
SME inspires, prepares and
supports the advancement of
manufacturing with industrybased
knowledge that is
shared through its members,
events, publications and
training programs. A 501(c)3
organization, SME is a leader
in manufacturing workforce
development issues, working
with industry, academic
and government partners
to support the current and
future skilled workforce.
Awards & Recognition
The International Awards & Recognition
Program honors the best and brightest for
their outstanding accomplishments
in manufacturing.
• International Honor Awards
• Award of Merit
• Outstanding Young Manufacturing
Engineer
• SME College of Fellows
• Many other technology-specific awards
• SOUTH-TEC®
• WESTEC®
• FABTECH®
• FABTECH-Canada
• FABTECH-Mexico
• CMTS — Canadian Manufacturing
Technology Show
• MMTS — Montreal Manufacturing
Technology Show
• NAMRC — North American
Manufacturing Research Conference
• RAPID Conference and Exposition
SME - Headquarters
One SME Drive
Dearborn, MI 48128
800.733.4763 | 313.425.3000
sme.org
Canadian Office
7100 Woodbine Avenue, Suite 312
Markham, ON L3R 5J2
888.322.7333
• SME Annual Conference
• PMDS — Plant Management and
Design Engineering Show
• WMTS — Western Manufacturing
Technology Show
Tooling U
3615 Superior Avenue
Bldg 44, 6th Floor
Cleveland, OH 44114
866.706.8665
toolingu.com

Manufacturing Engineering Media 2013
• Manufacturing Engineering® Media
is the premier source for news and
in-depth technical information about
manufacturing in North America in
both print and digital formats.
• MfgEngMedia.com
• Monthly magazine
• Mobile app
• Yearbooks provide in-depth industry
overviews of the Medical, Energy,
Aerospace & Defense and Motorized
Vehicle manufacturing industries.
• Monthly e-newsletters provide
concise and timely information on
industry news, technologies, process
innovation and case studies.
SME Officers
and Directors
President
Dennis S. Bray, PhD, FSME
Contour Precision Group LLC
President-Elect
Michael F. Molnar, FSME, CMfgE, PE
National Institute of Standards and
Technology
Professional
Development
Tooling U-SME training solutions
address manufacturers’ pressing
workforce challenges with industrydriven
content that aligns to
manufacturing job roles through:
• Books and Videos
• Outcome Assessments
• Certifications
• Competency Modeling
• Instructor-Led Training
• Instructional Design Services
• Learning Management System Tools
• Online Classes
• KnowledgeEdge SM
SME Education
Foundation
SME-EF inspires, supports and
prepares youth to pursue careers in
manufacturing and SME members for
their service to the society.
• Youth Programs — Funds K-14 STEM
programming.
• Scholarships for students
pursing degrees in engineering,
manufacturing and related fields.
• ManufacturingisCool.com
• PRIME (Partnership Response
In Manufacturing Education) —
Connecting the manufacturing
industry to classroom education.
Vice President
Wayne F. Frost, CMfgE
John Deere Waterloo Works (retired)
Secretary/Treasurer
Dean L. Bartles, PhD, FSME
General Dynamics Corporation
Directors
Joseph J. Beaman, ScD
University of Texas at Austin
Sandra L. Bouckley
Eaton Corp.
Edye S. Buchanan, CMfgT
Fives North American Combustion Inc.
LaRoux K. Gillespie, Dr. Eng., FSME,
CMfgE, PE
Honeywell (retired)
Edward G. Halloran, LSME, CMfgE, PE
HALCO Management Systems
Matthew L. Hilgendorf, CMfgT
Caterpillar Inc.
Thomas R. Kurfess, PhD, FSME,
CMfgT, PE
Georgia Institute of Technology
Robert R. Nesbitt, CMfgE
Eli Lilly and Company
A knowledge-delivery system
that compiles more than
18,000 SME-published
books, videos and technical
papers into a digitized
format under one userfriendly,
Web-based platform.
Michael D. Packer
Lockheed Martin Aeronautics Company
Susan M. Smyth, PhD
General Motors Corp.
© 2013_SME_8014

MEMBERSHIP APPLICATION
$138.00
$248.50
$352.00
$259.00 (for both)
$472.00 (for both)
$665.00 (for both
Department
o Automated Manufacturing & Assembly
o Forming & Fabricating
o Industrial Laser
o Machining & Material Removal
o Manufacturing Education & Research
o Plastics, Composites & Coatings
o Product & Process Design and Management
o Rapid Technologies & Additive
Manufacturing
Method of Payment: o Check/Money Order _______________
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Expiration Date ___________ CC Verf Code ________________
Signature ____________________________________________
o I want to sign up for the automatic renewal program. At renewal
time, we will charge your credit card the current membership
rate. Please contact SME Customer Care at 800.733.4763,
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opt-out of the automatic renewal program.
SME
Customer Care
This form valid through 6/30/13
13EX08

Join SMe today for access to
great member benefits and more
Be Part of SMe’S free
technical coMMunity network
• Get quick answers that help you solve problems NOW.
• access a broad and deep range of technical information suited
to your interests… even as they change.
• Stay current on emerging technologies and advances across the
manufacturingenterprise.
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professionals, online and in person.
• advance the collective knowledge in your specialty area of
interest by leading a tech group or guiding the development of
new information resources.
Indicate your selections in the “technical communities” section
on the front of this form.
AutomAted mAnufActuring & Assembly
Focuses on automated processes and technologies - the
integration of robotics, machine vision and sensors into
complete systems that manufacture and assemble products.
forming & fAbricAting
Supports key manufacturing technologies in metal forming and
fabricating, such as stamping, casting, shaping, bending, forging,
punching, cutting, welding, and other processes that add value to
sheet metal, coil, plate, tube, or pipe stock.
industriAl lAser
Actively engaged to promote Laser Technology in North America
with high intensity by educating the market and advancing the
laser technology base across all industry sectors with cutting,
welding, drilling, marking, surface treatment, and other advanced
laser applications.
mAchining & mAteriAl removAl
Focuses on machining processes, abrasive cutting processes,
cutting tools and tooling, metalworking fluids, machining
systems, machining of alternative materials, and
much more.
mAnufActuring educAtion & reseArch
Concentrates on the latest education and research in
manufacturing. Promotes manufacturing careers and educational
opportunities that enhance the diverse workforce needs of the
manufacturing enterprise.
PlAstics, comPosites & coAtings
Concentrates on engineered materials such as plastics,
composites, ceramics, and other advanced materials; decorative
finishing and coatings technologies, and metallurgy and
materials science.
Product & Process design and mAnAgement
Helps members implement proven models to increase company
productivity such as lean manufacturing, supply-chain
management, Six Sigma,and other quality-assurance
techniques.
rAPid technologies & Additive mAnufActuring
Focuses on solid freeform fabrication, or layered additive rapid
prototyping processes, including fused deposition modeling,
stereolithography, selective laser sintering, laminated object
manufacturing and 3-D printing.
areaS of intereSt
Help us meet your technical needs event better by further
“customizing” your membrship!
Choose up to four of the following areas of interest and
place their corresponding codes in “Areas of Interest”
section on the front of this application. SME will focus
on providing you with technology-specific information
relating specifically to these areas.
Aerospace Industry 1497
Assembly & Joining 6
Automotive Industry 1499
Composites Manufacturing 111
Computer-Integrated Manufacturing 1054
Consulting & Training Services 1446
Contract Manufacturing Services 1447
Education & Training Services & Institutions 316
Electronics Manufacturing 18
Environmental Manufacturing 1056
Finishing & Coating 376
Food Processing 1272
Forming & Fabricating 464
Lasers & Laser Systems 1485
Lean Manufacturing 66
Machining & Material Removal 760
Machine Vision Systems 60
Manufacturing Management 1206
Materials 331
Medical Device Industry 1503
Microelectromechanical Systems (MEMS) 1275
Micro Manufacturing 1489
Mold, Tool & Die Design 197
Nanotechnology 1276
NC, CNC & DNC 107
Packaging 191
Plant Engineering & Maintenance 1170
Plastics Molding & Manufacturing 1015
Process Design & Engineering 1161
Product Design & Automation 1157
Product Development 1155
Quality 1146
Rapid Prototyping 1136
Rapid Manufacturing 1137
Research & Development 1273
Robotics 92
Six Sigma 1121
Software, CAD/CAM 1118
Supply Chain Management 1077
© SME 2013

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Searching for answers just got better . . . and easier!
INTRODUCING THE NEWLY
REDESIGNED
WEBSITE . . .
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• More comprehensive and up-to-date site navigation
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• New and improved site search
• A NEW Learning Resource section
• A NEW Community section
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W H E R E T E C H N O L O G Y C O M E S F I R S T

SPECIAL PROGRAMS & ACTIVITIES
Dick Aubin Distinguished Paper Award
The paper selected for this award will describe an innovative
application of rapid prototyping processes and techniques. A
review committee comprised of members of the RTAM Tech
Community will determine the winner. Only papers accepted
for presentations at the RAPID conference will be considered
for the RTAM/SME Dick Aubin Distinguished Paper Award. The
award will be presented before the keynote presentations on
Wednesday, June 12. Award criteria and guidelines can be
reviewed at www.sme.org/aubinaward.
CASH AWARD! In addition to formal recognition and publication
of the paper, the principal author receives a check for $1000.
Funds donated by
Exhibitor Innovation Award
This award was designed to showcase the most innovative new
product displayed on the tradeshow floor. Exhibitors have been
invited to submit their best new product for considerations. A
jury of RTAM members will evaluate all submissions and select
5–10 finalists. Finalists will be identified on the show floor and
the winning innovation will be announced before the keynote
presentations on Wednesday, June 12.
Best in Show Award
This award, meant to highlight the best looking exhibit, will be
decided by the audience. Conference and show attendees will
receive a “ballot” type ticket with their registration credentials.
Vote for your favorite booth and drop your ballot in the designated
boxes. The results will be tallied through the registration system.
The winning booth will be announced before the keynote
presentations on Wednesday, June 12.
RAPID 2013 Puzzle Challenge
The 2013 puzzle was designed by RIT student Don Thompson.
RTAM/SME Industry Achievement Award
Established in 2008 by SME’s RTAM Tech Community, the RTAM/
SME Industry Achievement Award was developed to recognize
an individual, team or company for outstanding accomplishments
that have had significant impact within the additive
manufacturing industry or in any industry through the application
of additive manufacturing technologies. As the name suggests,
the award recognizes achievements that have been implemented
or deployed in a commercial/industrial environment rather
than research investigative work. Winners are selected with
consideration for the scope and scale of benefits realized and the
potential future impact their work will have on the industry.
The goal of the award is to recognize the development of
new technologies, materials and processes, or the creative
application of existing technologies, to solve problems
and create new opportunities. However, recipients are not
required to have played a direct role in the commercialization
of the technology. The award will be presented before the
keynote presentations on Wednesday, June 12. For eligibility
requirements visit www.sme.org/industryaward.
Each year the RAPID Puzzle Challenge helps attendees explore
the different additive manufacturing technologies and materials
represented on the show floor. This year’s puzzle—an apple—
features eight slices to collect and assemble.
Visit these exhibitors to complete your puzzle:
EnvisionTEC, Booth 402
EOS North America, Booth 313
ExOne, Booth 704
Harvest Technologies, Booth 412
Materialise, Booths 403 and 502
rapid prototype + manufacturing, Booth 302
Stratasys, Booth 604
American Precision Prototyping LLC, Booth 521
10 sme.org/rapid

Additive Manufacturing Briefings
This one-hour session, offered Tuesday and Wednesday during
lunch, is intended to provide show attendees with an introductory
overview of the additive manufacturing technologies and
companies on the show floor. Information gained will organize
your visit by identifying equipment, companies and processes that
fit your needs and interests. If you’re new to additive technologies
and want to gain a better feel for the major processes and
materials and how they can be applied to your applications, this is
the session for you.
The Additive Manufacturing Briefings are open to all registered
attendees.
3D Imaging Briefings
This one-hour session, offered Tuesday and Wednesday during
lunch, is intended to provide show attendees with an introductory
overview of scanning technologies and companies on the
show floor. Attendees receive a high-level overview of reverse
engineering, analysis and inspection. Attendees walk away with
a basic understanding of 3D imaging technologies and how the
technologies can be used to scan and produce anything from a
small part to a custom medical implant.
The 3D Imaging Briefings are open to all registered attendees.
3D Imaging
Medical Manufacturing Innovations (MMI)
Explore the MMI center on the RAPID show floor in Booth 912 to
see unique applications, meet medical manufacturing leaders and
hear more about medical opportunities at the MMI Learning Lab.
Informal presentations from those responsible for the showcased
applications and more will be made at the event and streamed
live on YouTube at www.youtube.com/user/SMEEvents/videos.
A schedule of presentations can be found at the MMI booth.
Contemporary Art Gallery
Sponsored by
Introduced at RAPID 2010, the Contemporary Art Gallery provides
artists familiar with design software and additive manufacturing
processes the opportunity to display their work to an appreciative
audience. Other artists had the opportunity to explore this new
medium by having their drawings transformed into actual works
of art using additive manufacturing to make the three dimensional
works for display.
The RAPID Conference offers a 3D Imaging & Scanning session,
which provides the latest information on 3D imaging applications
for inspection, quality, verification, metrology, measurement and
more. The focus of the session held on Tuesday, June 11, is on
using noncontact imaging technology to capture and process
high-resolution 3D spatial geometries. Learn how 3D imaging
technologies are being applied across several industries to achieve
cost-effective and accurate end products! A combination of case
studies and interactive, problem-solving discussions bring together
industry leaders to give you the most up-to-date information.
The Contemporary Art Gallery represents the use of additive
manufacturing in a whole new industry, expanding the horizons
and demand for these technologies. In 2013, the gallery includes
sculpture and jewelry designed by professional artists from
around the world. Make time to visit this display and see how
creative minds have dreamed and created incredible art!
6/2013 – RAPID 11

SPECIAL PROGRAMS & ACTIVITIES
Conference Kick-Off
Monday, June 10
2:30–5:30 pm
Experts from SME’s Rapid Technologies & Additive Manufacturing
(RTAM) Community Tech Groups review and highlight changes
and developments within the additive manufacturing industry.
These business leaders bring you up-to-date on the important
activities in this rapidly changing market and provide you with the
latest industry information.
KiCK-Off KeynOte:
fusing interaction and Physical World
Dr. ivan Poupyrev,
Director of Interaction Group,
Disney Research, Pittsburgh
In this presentation, Dr. Poupyrev will present work produced
by him and the research group that he has been directing at
Disney Research, Pittsburgh and which addresses the challenge
of blending the computation and physical worlds. He will cover
projects investigating tactile and haptics interfaces, deformable
computing devices, augmented reality interfaces and novel
touch sensing techniques, as well as biologically-inspired and
3D-printed interfaces, among others.
The presentation will cover both projects conducted while
at Sony Corporation and more recent research efforts in the
Interaction Group at Walt Disney Research, Pittsburgh.
20 for 20
Presented by SME’s RTAM Community
In celebration of RAPID’s 20th year as a conference and
exposition, the RTAM Community will present “20 for 20,” a brief
review of the great history of additive manufacturing, providing
key highlights that molded the manufacturing world into what it is
today and how it will shape the future.
12 sme.org/rapid

Trends. Analysis. Forecasts.
Your source for
everything
additive
manufacturing
■ Industry growth
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low-cost 3D printing
■ Nearly 60 coauthors
worldwide
with expert analysis
■ New: Sections
on China, Africa,
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ADVISORS
Event Advisors
Event Advisors have the responsibility for assisting SME with total
event planning including reviewing the makeup of the technical
advisor groups, assisting in speaker and abstract recruitment,
evaluating abstracts, and building relationships for the event
and the Rapid Technologies & Additive Manufacturing (RTAM)
community. They may also advise on various elements of the
event such as workshops, tours, technical briefings, keynotes,
technical sessions, media partners and the show floor.
indicates those advisors who are SME members
Greg Morris, RAPID Event Chair
GE Aviation
Greg Morris has been involved in the rapid
prototyping and manufacturing industry
since 1994, when he and two other partners
started Morris Technologies Inc. In 2007,
Morris and his partners founded another
company, Rapid Quality Manufacturing, to
focus on the production of additive metal
components aimed at the emerging aerospace, medical and other
markets. In November 2012, both MTI and RQM were acquired
by GE Aviation. In his new role with GE Aviation, Mr. Morris
is responsible for helping to advance the knowledge of and
applications for additive manufacturing technologies throughout
GE, and he works closely with the existing GE teams that have
been working with the technologies. Mr. Morris has written
numerous articles about additive manufacturing, with specific
emphasis on additive metals. He has also presented at various
trade shows, including SME’s RAPID Conference and Exposition,
Aerospace Design Expo, EuroMold, AeroTech, MoldMaking Expo
and PDx/Amerimold. Mr. Morris is the current chair of SME’s
Rapid Technologies & Additive Manufacturing Community.
Carl Dekker
Met-L-Flo Inc.
Carl K. Dekker serves as the president of
Met-L-Flo Inc., a growing service center for
additive manufacturing located in Sugar Grove,
IL. He has been actively involved in research
and product development using current
technologies and innovative methods.
Mr. Dekker has presented his work at various conferences
globally, including those sponsored by AMUG, Amerimold, ANTEC,
National Manufacturing Week, RAPDASA, RP&M, and SME. He
has also provided training and installations at Abbott Laboratories,
Delphi, Motorola and numerous other locations. Mr. Dekker’s work
has been published in industry journals including Prototyping
Technology, Rapid Prototyping Report, Time Compression
Technologies, and The Wohlers Report (2003-8) to mention a
few. A past chairperson of SME’s Rapid Technologies & Additive
Manufacturing (RTAM) Community (formerly the RPA), Mr. Dekker
currently serves as the chair of the Direct Digital Manufacturing
Tech Group of the RTAM. Being actively involved in fostering
education, he taught the RTAM Certificate Programs and also
remains active in the Bright Minds Program as a member and past
co-chair. He holds a Master Certificate in Rapid Prototyping and is
a proud recipient of the SLA “Dino” Award.
Past and present positions held include: Vice Chair of the ASTM
F42 Committee on Standards for Additive Manufacturing (2009-
2012), Industry Advisory Board Member for RapidTech (2010-
2012), RapidTech National Visiting Committee Chair (2011-2012),
T.E.A.M. NAB (Technician Education in Additive Manufacturing
National Advisory Board) Member 2011-2012, Museum of Science
and Industry Fab-Lab Advisory Board Chicago (2009-2012),
Editorial Advisory Board for Time Compression Technologies
Magazine (2007-2011), Waubonsee Community College Industry
Advisory Board (2008-10), Valley Industrial Association Board
Member (2009-12), RAPID Conference Advisor (2002-12), National
Design and Manufacturing Conference Advisor (2005), National
Plastics Exposition Conference Advisor (2006 and 2009), and
Secretary of the 3D Systems North American Stereolithography
Users Group (2003 and 2004). He has also served as the chair of
many specialty programs and conference sessions.
Dr. Mary Kinsella
United States Air Force
Mary E. Kinsella is a senior manufacturing
research engineer in the Materials and
Manufacturing Directorate, Air Force Research
Laboratory, Wright-Patterson AFB, Ohio. She
is currently assigned to the Manufacturing and
Industrial Technologies Division, where her
responsibilities include leading the Additive
Manufacturing Integrated Product Team. Dr. Kinsella has previous
14 sme.org/rapid

experience as the assistant chief scientist for the directorate and
as a program manager and section chief in metals processing.
Her research interests include additive manufacturing
technologies for aerospace applications. Dr. Kinsella received a
B.S. (Applied Science) degree in manufacturing technology from
Miami University in 1983, a MS degree in materials engineering
from the University of Dayton in 1991, and a PhD in industrial and
systems engineering from Ohio State University in 2004.
David K. Leigh
Harvest Technologies Inc.
David Leigh currently serves as president
of Harvest Technologies, an additive
manufacturing production company located
in central Texas. Harvest was one of the first
AS9100-certified companies to focus on the
demands of direct digital manufacturing in
the aerospace industry. Mr. Leigh has been a
champion for the LS process throughout his career, having served
as chairman of SME’s RTAM Steering Committee. He achieved his
B.S. and Masters of Science in mechanical engineering from the
University of Texas at Austin and is currently pursuing a PhD in
materials science. He worked at DTM Corporation in Austin as part
of the original team that commercialized laser sintering in the early
1990s. He left DTM and started Harvest Technologies in 1995.
in RP/AM technology and applications. Tromans has presented
numerous papers in the United States, Japan and Europe. He
is currently chair of the Additive Manufacturing Association in
the United Kingdom. Tromans is the editor of the “Developments
In Rapid Casting,” which is published by The Institute of
Mechanical Engineers in London, and is also a chapter author in
“Rapid Manufacturing—An Industrial Revolution For The Digital
Age,” primarily focusing within the book on automotive and
motorsports applications. In 2007, he became a Master-Level
Rapid Technologies & Additive Manufacturing Certificate holder;
to date, the first and only person from the United Kingdom to be
awarded this certificate. Tromans has also been awarded the
“Double Dino" Award in both SLA and SLS by the 3DSystems
Users Group, recognizing his long-term contributions to both SLA
and SLS technologies. Currently, he is an event advisor for SME’s
RAPID Conference and Exposition and former chair of the RTAM
Community. In 2005, he was voted the “Top 25 Most Influential
People in the World” in additive manufacturing.
Technical Advisors
Technical Advisors select one technical or industry area in
which to advise on technical content. Their responsibilities
include identifying potential presenters, reviewing and evaluating
technical abstracts and recommending abstracts to be selected
and developed into presentations for their specific area.
Graham Tromans
G.P. Tromans Associates
Graham Tromans is the principal consultant
and president of G.P. Tromans Associates, an
independent additive manufacturing and rapid
prototyping consultancy. Tromans has been
involved with additive technologies since 1990
when he was instrumental in the development
and technology application acceptance with
Rover Group, working with companies such as Land Rover,
BMW, Aston Martin, Ford Volvo and more recently Bentley
Cars, Boeing Aircraft, British Aerospace, F1 Racing, NASCAR,
Rolls Royce, Perkins Engines, JCB and many others. Tromans
was also responsible for setting up the Land Rover facility and
was an advisor to Jaguar Cars in establishing its facility. He has
represented the U.K. Government’s Department of Trade and
Industry on Overseas Science and Technology Experts Missions
to both the United States and Japan, looking at the developments
3D Imaging
Pierre Aubrey
ShapeGrabber Inc.
Giles Gaskell
Wenzel America Ltd
Michael Raphael
Direct Dimensions, Inc.
Casting
Tom Prucha
American Foundry Society
Thomas Sorovetz
Chrysler Group LLC
6/2013 – RAPID 15

ADVISORS
Creative Applications in Art
Kevin Ayers
Federal Bureau of Investigation
Nancy Hairston
VanDuzen SculptCAD
David Van Ness
Northern Arizona University
Final Part Production
Timothy Gornet
University of Louisville
Todd Grimm
T.A. Grimm & Associates
Ryan Larson
Nike Inc.
Terry Wohlers, FSME
Wohlers Associates
Innovative Applications
Abbey Delaney
Materialise USA
Sheku Kamara
Milwaukee School of Engineering
Scott Schermer
SC Johnson & Son
Arif Sirinterlicki, PhD
Robert Morris University
Medical
Martin Bullemer
EOS Electro Optical Systems GmbH
Andy Christensen
Medical Modeling Inc.
Stephen Rouse, PhD
Consultant
Janelle Schrot
Materialise USA
Printed Materials
Denis Cormier
Rochester Institute of Technology
Vesna Cota
Tyco Electronics Canada
Jeff Duce
Boeing
Scott Johnston, PhD
Boeing
Product Design
Mark Adkins, NPDP
Smart Hammer Innovation
Michael Block
Stratasys Inc.
Gary Lowell
DASI Solutions
Randy Rossi
Bally Design
Transportation
Boris Fritz
Northrop Grumman Aerospace Systems
Steve Griffiths
Materialise USA
Scott Killian
EOS of North America
16 sme.org/rapid

Careers in TeChnology
Bright Minds Mentor Program
Sponsored by
students are provided industry-related materials, parts and
scholarship information. Students are encouraged to share
what they have learned with their fellow students and teachers.
The Bright Minds Mentor Program will take place Wednesday,
June 12 during show hours. Learn more about the Bright Minds
Mentor Program at www.sme.org/brightminds.
Members of the RTAM Education & Information Exchange Tech
Group will hold the 10 th annual mentoring program. This year’s
program participants include students in the Pittsburgh area.
The program creates interest, excitement and an appreciation
for product development and rapid technology applications
among the high school students. Students are paired with
industry professionals as mentors who guide them through the
conference and exposition hall. Students are allocated a portion
of time to pair off with each other to experience the sessions
and exhibits without the mentors. To enhance their participation,
Design for DDM Student Competition
This annual student-only competition encourages student
designers to use their imaginations to design a product
intended to be, or be part of, a system that utilizes direct digital
manufacturing (DDM) features. The product must be able to be
used in another assembly, and it needs to be fabricated mainly
using DDM processes. The competition is open to university,
college, technical and high school students. The winning
design will be announced before the keynote presentations on
Wednesday, June 12.
#1
IN THEWORLD
18 sme.org/rapid

G e t t h e l a t e s t t e c h n i c a l i n f o r m a t i o n o n . . . . .
r a p i d p r o t o t y p i n g a n d
3 D p r i n t i n g i n
M a k e P a r t s F a s t ,
p u b l i s h e d f o u r t i m e s
a y e a r .
www.makepartsfast.com • www.designworldonline.com

SponSorS & SupporterS
About SME
SME is the premier source for
manufacturing knowledge,
education and networking. Through
its many programs, events,
magazine, publications, and online training division, Tooling U,
SME connects manufacturing practitioners to each other, to the
latest technologies and to the most up-to-date manufacturing
processes. SME has members around the world and is supported
by a network of chapters and technical communities. A 501(c)3
organization, SME is a leader in manufacturing workforce
development issues, working with industry, academic and
government partners to support the current and future skills
workforce. Visit www.sme.org to learn more.
About RTAM
The quickest way to get an answer to a complex problem is to
ask someone who understands what you do and how to apply the
solution. That’s the philosophy behind SME’s large, but specialized,
“people network” that comprises the Technical Community
Network. The Rapid Technologies & Additive Manufacturing
(RTAM) Community includes various tech groups that connect
group members by providing the channel for knowledge sharing.
Membership in the community and one or more tech groups is
open to any SME member at no additional charge. Visit the SME
Resource Center, Booth 913, to meet others with similar interests
and learn more about the community network and how you can
get involved. Read on to discover a few of the activities within the
RTAM community. Visit www.sme.org/rtam to learn more.
RTAM Tech Groups
The RTAM Tech Groups will participate in a “Meet and Greet” at
the Networking Reception on the show floor on Tuesday, June 11
in the SME Resource Center, Booth 913. Stop by to meet members
of the group and other industry supporters. Find out what the
groups are doing and hear about opportunities for involvement
within the RTAM Community of SME tech groups.
3D Imaging
The tech group’s focus is on processes that combine hardware
and software technology to capture 3D spatial measurement data
for the creation of 3D digital representations of physical objects
for downstream applications.
Direct Digital Manufacturing
Direct digital manufacturing (DDM) is the process of going
directly from an electronic digital representation of a part to the
final product via additive manufacturing. Advancement of DDM
into high volume production methods will compete with traditional
manufacturing processes.
Medical Applications
The group is interested in the medical application of rapid
technologies and additive manufacturing to design and create
custom devices, medical models, equipment and medical
instruments.
Nanomanufacturing
The group provides a base for members interested in leadingedge,
practical information about the latest nanomanufacturing
engineering design and manufacturing techniques, whether topdown
or bottom-up. The group’s focus is on nanomanufacturing
technologies, materials and processes that are mature enough
for use, with an emphasis on additive manufacturing processes.
Education and Information Exchange
The group is responsible for the Bright Minds Mentor Program,
which aims to create interest, excitement and an appreciation
for product development methods, rapid technologies and
applications among high school students.
National Additive Manufacturing
Innovation Institute (NAMII) at RAPID
NAMII is a public-private partnership with member organizations
from industry, academia, government, and workforce
development resources all collaborating with a singular, shared
vision. Its goal is to transition additive manufacturing technology
to the mainstream U.S. manufacturing sector and create an
adaptive workforce capable of not only meeting industry needs
but also increasing domestic manufacturing competitiveness.
Learn more about NAMII at www.namii.org.
20 sme.org/rapid

NAMII on the Show Floor
Tuesday, June 11
8 am–7 pm
Wednesday, June 12
8 am–3 pm
Visit NAMII in Booth 902 to learn more about the institute and
how it plans to transition additive manufacturing technology to
the mainstream US manufacturing sector.
NAMII Roadmap Overview
Tuesday, June 11
9:30–10 am in the Keynote Theater
Be among the first to see and learn about NAMII’s roadmap. Rob
Gorham, Deputy Director of Technology for NAMII, will present
the initial work, how it was designed and the plan moving forward
for the institute. This presentation is optional and will follow the
morning keynote presentations.
Event Sponsors
The RTAM community of SME extends sincere gratitude to
the following companies for their support of the RAPID 2013
Conference and Exposition.
The company’s founders have always had one main objective:
striving to develop new products that add real value to a
designer’s, patient’s or toolmaker’s work and life. The company
mission statement is “to innovate product development
resulting in a better and healthier world through its software
and hardware infrastructure and in-depth knowledge of additive
manufacturing.” Visit Materialise in Booths 403 and 502.
3DP provides design flexibility and significant time savings over
traditional manufacturing methods. Visit ExOne in Booth 704.
Geomagic is a subsidiary of 3D Systems, a leading global provider
of 3D content-to-print solutions including 3D printers, print
materials and on-demand custom parts services for professionals
and consumers alike. The company also provides CAD modeling,
reverse engineering and inspection software tools and consumer
3D printers, apps and services. Its expertly integrated solutions
replace and complement traditional methods and reduce the
time and cost of designing and manufacturing new products.
3D Systems’ products and services are used to rapidly design,
communicate, prototype or produce real functional parts,
empowering customers to create and make with confidence.
Stratasys Ltd. was formed by the merger of 3D printing companies
Stratasys Inc. and Objet Ltd. The company manufactures systems
and materials for prototyping and production. Its patented
FDM® and Polyjet®-based processes produce prototypes or
manufactured goods directly from 3D CAD files or other 3D
content. Systems include affordable desktop 3D printers for
idea development, a range of systems for prototyping, and
large production systems for direct digital manufacturing. The
company’s 130 materials include more than 120 proprietary
photopolymer materials and 10 proprietary thermoplastic
materials. Visit Stratasys in Booth 604.
NCP Leasing Inc. specializes in financing rapid prototyping
systems and other high technology capital equipment.
The ExOne Company supplies services, systems and solutions for
additive manufacturing using three-dimensional printing (3DP)
in metal, glass and sand. The 3DP process builds an object—or
mold for an object—layer by layer out of powdered material, a
chemical binder and a digital file. Industrial-strength materials
are used to create prototypes and short-run production parts.
SLM Solutions GmbH, a pioneer in the sector of Rapid
Manufacturing Systems, has served customers in the fields of
Vacuum Casting, Metal Casting and Selective Laser Melting
for more than 50 years. Focused industries are automotive,
6/2013 – RAPID 21

SponSorS & SupporterS
education, consumer electronics, aerospace and medical.
As a pioneer in this field, SLM Solutions is developing and
producing specific and economical solutions for its customers.
The company has long-time know-how in Rapid Prototyping
processes and customer areas. This knowledge was acquired
under the previous company setups and names HEK GmbH, MCP
HEK Tooling GmbH, MTT Technologies GmbH and finally SLM
Solutions GmbH. In 2010, SLM Solutions GmbH was separated
from the previous MTT Technologies Group to improve flexibility
in enhancing innovative products and solutions for generative
system technology as ALM and SLM.
Media Partners
GARPA
The Global Alliance of Rapid Prototyping Associations (GARPA)
and its annual meeting, the Global Summit, were formed to
encourage the sharing of information on rapid prototyping and
related subjects across international borders. As a part of this
sharing, GARPA members from around the world participate
in activities that include technical presentations at industry
conferences, the publication of application case studies,
business meetings, social events, and the formal and informal
exchange of information. The SME RTAM Community is a member
of GARPA. Learn more about GARPA at www.garpa.org.
Supporting Partners
Media and Supporting Partners
SME extends its thanks to the following media and supporting
partners. They have worked collaboratively with SME to promote
RAPID 2013 to their respective audiences to maximize awareness
and increase participation in this event.
22 sme.org/rapid

SME Upcoming Events
2013
CMTS—
Canadian Manufacturing Technology Show
September 30–October 3
Mississauga (Toronto), Canada
WESTEC ®
October 15–17
Los Angeles, California
SOUTH-TEC ®
October 29–31
Greenville, South Carolina
FABTECH ®
November 18–21
Chicago, Illinois
2014
AeroDef Manufacturing
February 26–28
Long Beach, California
FABTECH ® Canada
March 18–20
Toronto, (Ontario) Canada
FABTECH ® Mexico
May 6–8
Mexico City, Mexico
Mfg4—Manufacturing 4 the Future
including MicroManufacturing
May 6–8
Hartford, Connecticut
Composites Manufacturing
May 13–15
Covington, Kentucky (Cincinnati area)
The Big M, co-located with:
RAPID Conference & Exposition
SME Annual Conference
NAMRC
June 10–12
Detroit, Michigan
FABTECH ®
November 4–6
Atlanta, Georgia
Dates subject to change. For additional information, contact
SME Customer Care at 800-733-4763, from 8 am to 5 pm (ET)
Monday through Friday. Or visit www.sme.org and click
on “Events.”
WESTEC ® and SOUTH-TEC ® are co-sponsored by
The Association For Manufacturing Technology.
CMTS and MMTS are co-sponsored by Canadian Machine
Tool Distributors’ Association and Canadian Tooling &
Machining Association.
The FABTECH ® series of events is co-sponsored by
Fabricators & Manufacturers Association, International,
American Welding Society, Precision Metalforming
Association and the Chemical Coaters Association
International.
MMTS—
Montreal Manufacturing Technology Show
May 12–15
Montreal, Canada
6/2013 – RAPID 23

At-A-Glance
RAPID 2013
June 10-13 | David L. Lawrence Convention Center | Pittsburgh, Pennsylvania
8:00 AM
Monday, June 10
Registration
9:00 AM - 1:30 PM
Workshops
Fundamentals: Additive Manufacturing
Fundamentals of 3D Scanning and
3D Modeling
Metal Parts Using Additive Technologies
Fundamentals of RTV Mold-making and
Polyurethane Casting
2:30 PM - 5:30 PM
5:30 PM -10:00 PM
7:00 AM - 6:00 PM
8:00 AM
Conference Kick-off featuring Dr. Ivan Poupyrev, Director of Interaction Group at Disney Research Pittsburgh Laboratory
including RTAM: 20 for 20
Opening Reception at the Andy Warhol Museum (registration required)
Tuesday, June 11
Registration
KEYNOTE
Brett B. Lambert, Deputy Assistant Secretary of Defense for Manufacturing and Industrial Base Policy, Department of Defense
Michael F. Molnar, Chief Manufacturing Officer, National Institute of Standards and Technology
Ed Morris, Director, NAMII
NAMII Roadmap Overview
Rob Gorham, Deputy Director of Technology, NAMII
Exhibits Open until 7:00 PM
AM SESSIONS
10:00 AM - Noon
Applications for Transportation
including Aerospace and Aircraft
Medical and Dental Applications
Additive Manufacturing Applications I
Creative Uses for Art, Architecture
and More
Design Study on an Additively
Manufactured Compressor Casing
Containing Auxetic Structures
Development of a Lightweight Hydraulic
Valve Manifold by Selective
Laser Melting Technology
Medicine Meeting AM Technology: Close
Encounters of the Third Kind?
IT Enabled Technologies Disrupt
Manufacturing
Breaking the Mold - 3D Printing
Engineering Grade Ceramic Materials
The Factory 2.0: the RAPIDLY Evolving
Relationship Between Art and
Additive Manufacturing
Making it Personal
New Machine X Line 1000R & Case Studies
of Metal Additive Manufactured Parts
Implemented in Aerospace Industry
Direct Comparison of DMLS and
EBM Ti6Al4V Performance in Vivo
Unisource Engineering Solutions Uses
Mcor 3D Printing to Make More Realistic
Packaging Prototypes
Merging Digital and Physical Processes
in Architectural Design and Fabrication
Noon - 1:00 PM
Noon - 1:30 PM
PM SESSIONS
1:30 PM - 5:00 PM
Selective Laser Sintering (SLS) of Next
Gen Unmanned Air Vehicles (UAVs)
Additive Manufacturing Tech Briefing
Additive Manufacturing for Surgical
Implants: It's the Present and the Future
Lunch on the Show Floor
Evaluating Your 3D Printing Options:
Advice from the Experts
3D Imaging Tech Briefing
Precious Metals in
Additive Manufacturing
Final Part Production Medical and Dental Applications (cont) Additive Manufacturing Research 3D Imaging & Scanning
A Case Study in the Use of
Additive Manufacturing
as a Viable Production Process
Using Additive Manufacturing to
Produce Custom Prosthetic Attachments
for Wounded Warriors
Laser Additive Manufacturing
of Pure Copper
Preserving the Past, Developing
the Future - A Collaboration
of Emerging Technologies
Battlefield Printing of Surgical
Instruments by
Fused Deposition Modeling
Design and Fabrication of a Variable
Impedance Prosthetic Socket Through
Multimaterial 3D Printing Techniques
Powder-Based Electron Beam Additive
Manufacturing - Process Modeling with
Applications to Novel Overhang
Support Designs
Structured Light 3D Scanning
Fundamentals
Additive Manufactured Modular
Telescoping Wing Unmanned
Aerial Vehicle
Guided Decision Making in Aortic Aneurysms
Using Patient Specific 3D Reconstructions
and Printed Models: A Case Study
Modeling and Validation of Residual Stress
and Distortion in Direct Metal
Deposition Processes
Wearable Technologies Benefit
From 3D Imaging
Global Advances in Metal Additive
Manufacturing for Final Part Production
3D Printing Advances Patient-Specific
Biomedical Engineering Modeling
and Experimentation
Designing and Building Open Source
Rapid Prototyping Machines
Determination of a Scaling Factor
for Use in an Electron Beam Melting
Additive Manufacturing Machine
Additive Manufacturing - A Critical Review
Streamlining the Biomodeling
and Biomedical Design and
Development Processes
Additive Manufacturing's Role in the
Development of Safe, Compact,
Integrated Fluid Power Systems
Tessa's Eyes - An Effort to Help Protect
a Little Girl's Eyes
Sustainable Cars and the
Future of Manufacturing
Continuous Digital Light Processing (cDLP)
for the Highly Accurate 3D Printing of
Tissue Engineering Bone Implants
Laser Additive Manufacturing for
Blow Mould Applications
Optical Inspecting via Structured
Light Scanning – KNOW What You Made
and Prove It!
Panel Discussion
This panel is composed of experienced
practitioners, users of additive manufacturing to
build parts. It will discuss the benefits and
challenges of bringing AM into production and
printing final parts. The finished parts contribute to
lower labor cost, speed up assembly times and
increase final product quality.
Customized Surgical Instrument for
Maxillofacial Surgery by SLM:
Case Study, Process Steps,
Powder Specifications
Process Mapping Methods for Integrated
Control of Melt Pool Geometry and
Microstructure in Direct Metal Additive
Manufacturing
The Fastest Path from Scan to CAD
24 sme.org/rapid
5:30 PM - 7:00 PM Networking Reception on Show Floor
Printed May 10, 2013. Please use the Onsite Pocket Guide for the most up-to-date schedule including presentation times and room assignments.

7:00 AM - 2:00 PM
8:00 AM
Wednesday, June 12
Registration
KEYNOTE
Additive Manufacturing: State of the Industry
Terry Wohlers, Wohlers Associates
Exhibits Open until 3:00 PM
AM SESSIONS
10:00 AM - Noon
Additive Manufacturing Applications II
Casting
Product Design Considerations
Using Additive Manufacturing
Direct Write Printed
Materials/Electronics
Case Study: Gas Ejector Nozzle
Made by Metal Laser Sintering
Integrating Design Efficiency with Additive
Manufacturing to Improve Time to Market
Seminar
3D Printing's Role in Product
Development: CaliBowl Case Study
Printed Optics: Interactive Objects and
Devices using Optically Clear Materials
and Embedded Components
Noon - 1:00 PM
Noon - 1:30 PM
PM SESSIONS
1:00 PM - 3:30 PM
Metal Laser Sintering System
Comparison, Product Quality
and Material Properties
Conformal Cooling
Metal Additive Manufacturing Goes
Bigger and Faster to Meet the
Manufacturing Challenges of Tomorrow!
Innovative Applications
Hosted by the American Foundry Society (AFS),
this seminar provides you with an interactive
overview of various metalcasting processes and
alloys so that you can make better design and
sourcing decisions for your engineered cast
components. The application of adaptive
manufacturing and rapid prototyping technology
to assist in reducing the time and cost to develop
new component designs and also examples of
conversions from other manufacturing process
will be discussed. An informed designer and
purchaser by understanding how the proper
material/process marriage can unleash the power
of metalcasting will be better equipped to create
the most cost effective product.
Additive Manufacturing Tech Briefing
Casting (cont)
A Process Workflow for Designing
Finished Parts for Additive Manufacturing
Panel Discussion
This panel is composed of designers and
engineers from some of Pittsburgh's leading
manufacturers. It will discuss the benefits and
challenges of bringing AM into the new product
development area. New designs that reduce part
count, lower labor cost, speed up assembly times
and increase part strength are all potential
benefits of AM. Are they being realized in today's
leading innovation organizations?
Lunch on the Show Floor
Product Design Considerations Using
Additive Manufacturing (cont)
3D Imaging Tech Briefing
Complete Electrical Assemblies Made
with Additive Manufacturing: Medical
Applications
Fabrication and Characterization of
3D Printed Compliant Tactile Sensors
Capability Assessment of Combining
3D Printing (FDM) and Printed Electronics
(Aerosol Jet) Processes to Create Fully
Printed Functionalized Devices
Direct Write Printed
Materials/Electronics (cont)
3D Imaging and Forensic Reconstruction
of the Human Face
Magnesium Prototypes Now
Additive Manufacturing and Innovative
Design: Working “Hand in Glove” to Create
the Next Generation Products
Direct-Write and Printed Electronics
in Aerospace
Sky's the Limit: Advanced Rapid
Prototyping with Multi-material Capabilities
Light Cured 3D Sand for
Rapid Casting Technology
Using 3D-Color Coding to Communicate
Design Intent
Direct Write Printing of Sensors,
Antennas & Circuitry
Making Stuff in the Connected Age
Case Study: Creating a Large Prototype
Pump Impeller Using a QuickCast Pattern
How to Design for Additive Manufacturing
Technology Direct Metal Laser Sintering
(DMLS)
Pulsed Photonic Curing of Printed Functional
Materials
Advantages of Selective Contour
Photocuring (SCP) Technology for
Additive Manufacturing
Utilize Ancient Casting Techniques and 3D
Printing Technology to Accelerate
Direct Manufacturing Processes
Legal and Policy Issues Connected
to Consumer Use of 3D Printing
3D Structural Electronics Fabrication
Using Fused Deposition Modeling and
Direct-Write Microdispensing
Design Innovations Enabled by
Additive Manufacturing
Using Additive Manufacturing
to Enhance Prototype Castings
Intellectual Property Issues in
Additive Manufacturing
RF Printed Circuit Structures Using a
Commercially Available Direct Print Tool
3:30 PM Tour: Bally Design
Thursday, June 13
9:00 AM - Noon Tour 1: ExOne & threeRivers3D
Tour 2: Human Engineering Research
Laboratories at Univ of Pittsburgh &
TechShop Pittsburgh
Printed May 10, 2013. Please use the Onsite Pocket Guide for the most up-to-date schedule including presentation times and room assignments.
6/2013 – RAPID 25

Workshops & Tours
Concurrent Workshops
Monday, June 10
9 am–1:30 pm
Registration required.
Attendance at any of the Monday workshops includes a box
lunch and admission to the Conference Kick-Off and the
exposition on Tuesday and Wednesday.
Fundamentals: Additive Manufacturing
Graham Tromans, G. P. Tromans Associates
This workshop introduces participants to the world of additive
manufacturing technologies with discussions on the most widely
used technologies and how they are applied.
Fundamentals of 3D Scanning and 3D Modeling
Giles Gaskell, Wenzel America Ltd.
This workshop provides a comprehensive introduction to 3D
scanning technologies, software and processes, highlighting the
differences among data capture technologies, followed by a handson
demonstration of some of the most popular scanning devices.
Metal Parts Using Additive Technologies
Frank Medina, University of Texas at El Paso
This workshop provides an overview of additive processes used
for creating metal parts. Methods for metal part fabrication
range from casting metal parts from rapid-prototyped patterns
to direct metal fabrication using lasers, electron beams or
ultrasonic energy.
Fundamentals of RTV Mold-making
and Polyurethane Casting
Bill Molitor, Innovative Polymers
Myra Bumgardner, Silicones Inc.
Terry McGinnis, BJB Enterprises
This workshop will create an opportunity for model shops,
prototypers, designers and others to learn about the use of
silicones for creating molds and polyurethanes for creating cast
parts in silicone tooling. The panel will also discuss advantages
of using RTV tooling and polyurethane casting to expand your
manufacturing capabilities beyond prototypes into rapid short-run
and medium-run production.
Concurrent Tours
Wednesday, June 12
3:30–6 pm
Cost: $30 (registration required)
Transportation will only be provided in the event of inclement
weather.
Bally Design
Located in the heart of Pittsburgh’s cultural district, Bally
specializes in product design and development, engineering,
branding, corporate identity, and environmental design. This
event provides an opportunity to participate in a creative exercise
on product design and network while enjoying a “taste of
Pittsburgh.” See the tools and techniques that drive innovation
and creativity in product design for industrial, medical and
consumer products—all by design.
Thursday, June 13
8:30 am–12:30 pm
Select Tour #1 -OR- Tour #2
Cost: $80 (registration required)
Transportation provided
Tour #1: ExOne & threeRivers 3D
Visitors will view ExOne’s 3D metal printing process from start
to finish as well as be one of the first to tour their cutting-edge
machine build lab. Get up-close and examine a large variety of
metal parts and printed sand molds representing the spectrum of
industrial additive manufacturing.
26 sme.org/rapid

Visitors will see the manufacturing of 3D scanners. threeRivers
3D will detail their local sourcing strategy and the benefits of a
close-to-the-vest supply chain. Visitors will follow the mechanical
assembly of the scanner core, burn-in and final assembly/
validation. Also provided will be a demonstration of 3D scanning
in general.
Tour #2: Human Engineering Research Laboratories
at VA Pittsburgh & TechShop Pittsburgh
TechShop is a community-based workshop and prototyping studio
on a mission to democratize access to the tools of innovation.
Their seventh and newest location, TechShop Pittsburgh,
will offer the Pittsburgh maker community more than 16,000
square feet of workshops equipped with world-class tools and
equipment, computers loaded with design software featuring the
Autodesk Design Suite, hundreds of classes each month, and the
support and camaraderie of a community of like-minded makers.
HERL’s mission is to continuously improve the mobility and
function of people with disabilities through advanced engineering
in clinical research and medical rehabilitation. Visitors will
see projects under design with final parts made with additive
manufacturing and a full operating laboratory that includes
operating equipment.
Thursday Tour Note: Tour participants may be dropped off at the
conclusion of the tour at either the airport or the Omni Hotel.
Tour #1 will go to the airport first, and then return to the hotel;
Tour #2 will go to the hotel first, then to the airport. The tour
buses can accommodate luggage. The intention is to arrive
at the airport by approximately 1 pm from both tours. Please
schedule your flight accordingly.
6/2013 – RAPID 27

Contemporary art Gallery
The Contemporary Art Gallery is located on the show floor. There
are over 30 pieces displayed that beautifully demonstrate the
capacity and versatility of additive manufacturing technologies.
For more information about the artists, their backgrounds, and
the processes used to create each work of art, please visit the
Contemporary Art e-Gallery at www.sme.org/rapid.
Marlon Artis
“Bouquet—Champagne/Wine Bottle Sleeve”
Shelle Carrig
“The Medium is the Message”
Douglas L. Cook
“Lattice Bloom”
Vito Gervasi
“Harmony”
Joshua Goode
“Wooly Mammoth Tooth and Golden Mammoth Tooth”
Heather Gorham
“Vehicles and Animals”
Bathsheba Grossman
“Crosstalk”
“Balancing Squid Bottle Opener”
“Hyperwine”
“Nekton”
“Double Zarf”
Patricia deLarious
“Manphibian”
Jessica Rosenkrantz
“Orbicular Lamp”
Image courtesy John O’Sullivan
28 sme.org/rapid

Steven Hopwood-Lewis
“Bust of a Youth”
Monika Horcicová ˘
“The Wheel of Life”
Elliott Johnson
“I Wasn’t Before, but I Am Now”
Josh King
“1,700 Cubic Meters”
John O’Sullivan
“Vascular Collar of White Flexible Polyamide”
Shane Pennington
“Solstice”
Dario Scapitta
“EXTRAVAGANZA Armband”
Shawn Smith
“Ram Head”
Jim Stanis
“BlobCube”
David Van Ness
“Head of Baby”
The Factory 2.0
The following artists’ pieces are on loan to RAPID from
Materialise. These pieces were displayed as part of The Factory
2.0 Installation—curated by Murray Moss—at the Andy Warhol
Museum. The installation was presented at the RAPID 2013
Opening Reception on Monday, June 10.
Image courtesy Jessica Rosenkrantz
Eric van Straaten
“3D Printed Sculpture”
Thomas Cornelis
“Cowbox”
Mary Visser
“Rapid Prototyped Sculpture”
Emanuele Niri
“Tomato Paint Soup”
Andrew Werby
“Redcolinks”
Cathrien Orie
“Trash Can”
Dominik Raskin
“Double Elvis”
Luigi Vaghi
“Speaking Into the Microphone”
6/2013 – RAPID 29

Keynote Presentations
Monday, June 10
2:30–5:30 pm
KicK-Off KeynOte:
fusing interaction and Physical World
Dr. ivan Poupyrev,
Director of Interaction Group,
Disney Research, Pittsburgh
tuesday, June 11
8–9 am
Keynote Presentations
the future of Additive Manufacturing
and introduction to nAMii
Brett Lambert, Deputy Assistant Secretary
of Defense for Manufacturing and Industrial
Base Policy
In this presentation, Dr. Poupyrev will present work produced
by him and the research group that he has been directing at
Disney Research, Pittsburgh and which addresses the challenge
of blending the computation and physical worlds. He will cover
projects investigating tactile and haptics interfaces, deformable
computing devices, augmented reality interfaces and novel
touch sensing techniques, as well as biologically-inspired and
3D-printed interfaces, among others.
Brett Lambert will discuss how the Department of Defense plans
to implement additive manufacturing in the future.
Michael f. Molnar, Chief Manufacturing
Officer, National Institute of Standards
and Technology (NIST)
The presentation will cover both projects conducted while
at Sony Corporation and more recent research efforts in the
Interaction Group at Walt Disney Research, Pittsburgh.
Mike Molnar will discuss the importance of additive
manufacturing in US commerce now and in the future,
as well as his vision of manufacturing in our economy.
edward Morris, Director,
National Additive Manufacturing
Innovation Institute (NAMII)
Ed Morris will provide an introduction to the National Additive
Manufacturing Innovation Institute (NAMII), which is working
to transform the US manufacturing sector and yield significant
advancements throughout the industry.
30 sme.org/rapid

NAMII Roadmap Overview
9:30 am
Wednesday, June 12
8–9 am
Additive Manufacturing: State of the Industry
Terry Wohlers,
President, Wohlers Associates
Be among the first to see and learn about NAMII’s roadmap.
Rob Gorham, Deputy Director of Technology for NAMII, will
present the initial work, how it was designed and the plan
moving forward for the Institute.
Additive manufacturing and 3D printing are taking the world
by storm, while gaining the attention of the largest and most
respected corporations and publications. New machines,
applications, and markets are developing like never before.
Wohlers will discuss some of these developments and report
industry growth figures, estimates, and forecasts. He will also
present some of the most important trends, both current and long
term. He will close with his views on what the future holds for this
exciting and fast-changing industry.
6/2013 – RAPID 31

NetworkiNg receptioNs
Two receptions will be held at RAPID 2013.
Monday, June 10
5:30–10 pm
Opening Reception at the Warhol Museum
Tuesday, June 11
5:30–7 pm
Networking Reception on the Show Floor
Cost: Included with registration
Cost: $60 (registration required)
Sponsored by
Sponsored by
Murray Moss, Curator and Creative Director of Moss Bureau, and
Materialise will present Factory 2.0, featuring a 2D/3D interactive
stereolithography installation and the Forum of Stephen Jones,
created by the British Milliner.
Join other attendees and exhibitors on Tuesday evening for a networking
reception on the show floor with light hors d’oeuvres and
a cash bar. Keep the interaction going while you network with
peers, discuss applications with speakers and colleagues and
continue discussions with exhibitors in a relaxed environment.
Conference attendees receive refreshment vouchers.
The installation will illuminate the RAPIDly evolving relationship
between Art and Additive Manufacturing, focusing on innovations
which are changing how Art is conceived and made, particularly
through the use of Materialise’s proprietary Mammoth
Stereolithography technology, which is able to realize previously
unrealizable mammoth works of art. In the museum’s famous Time
Line Gallery, renowned British Milliner Stephen Jones has been
commissioned to create a monumental work, also addressing
both Warhol and Additive Manufacturing.
Also at this reception, Materialise will announce the winner
of the Andy Warhol Challenge, a competition sponsored by
i.Materialise that encourages artists to design what they think
Andy Warhol would have produced with 3D printing technology
if he were alive today.
Hors d’oeuvres, beer and wine will be served throughout the
evening.
32 sme.org/rapid

ANTICIPATES YOUR
CASTING NEEDS
AFS is committed to facilitating the connection between casting supplier and casting buyer,
offering programs, literature and classes for designing and purchasing castings, as
well as tools to match the appropriate casting supplier to your application.
DESIGN SOLUTIONS FOR
SUCCESSFUL CASTING DESIGN
• Casting process design & simulation
• Product performance test evaluations
• Prototyping and production sourcing
BOOST KNOWLEDGE WITH
EDUCATION AND TRAINING
Upcoming courses include:
• Aluminum 101: An Introduction to Aluminum &
Aluminum Casting Processes (Aug. 14)
• Analysis of Casting Defects (Aug. 27-28)
• Introduction to Metalcasting (Sept. 10-11)
FIND A CASTING SUPPLIER
Our online directory of North American metalcasters
helps you search by location, alloy, process, size limits,
and production requirements.
ALLOY AND PROCESS SELECTION AIDS
Our web-based tools direct you to the right alloy and
casting method to make your next part.
METALCASTING LITERATURE
• The online AFS Library holds thousands of
metalcasting-related papers and articles.
• AFS’s E-Store offers dozens of textbooks and other learning aids.
Scan the QR code to visit the AFS webpage on a smartphone, using a smart phone app.
Download the QRReader app from your smartphone’s App Store.
www.afsinc.org • 800/537-4237

ConferenCe Details
Tuesday, June 11
Applications for Transportation
including Aerospace and Aircraft
10 am–Noon
The session will combine applications using additive
manufacturing for parts and models used in motor vehicles,
commercial and military aircraft, and aerospace.
10–10:25 am
Design Study on an Additively Manufactured
Compressor Casing Containing Auxetic Structures
David Rockel, Dipl.-Ing., Research Associate,
Institute for Flight Propulsion - TU Muenchen
This session will present a new potential application of additive
manufacturing technologies in future aero engine design,
and focus on the practical implementation of the new design
freedom using the example of a compressor casing. The results
show a clear improvement of the tip clearance behavior of the
casing. Design elements are developed in order to adapt the
casing expansion to the rotor throughout an entire load cycle of
an aero engine.
11–11:25 am
New Machine X Line 1000R & Case Studies
of Metal Additive Manufactured Parts Implemented
in Aerospace Industry
Andreas Tulaj, Dipl.-Ing., Regional Sales Manager, Concept Laser
GmbH
C. Malcolm Ward-Close, Professor, Imperial College London
Additive manufacturing with metals is becoming increasingly
important in many areas of industry. Time and cost reductions
in production are making this generative technology more
and more attractive even for medium-sized quantities and
larger components.
With this in mind, Concept Laser, together with the Fraunhofer
Institute for Laser Technology (ILT) and the automotive partner
from industry Daimler AG developed a new high-performance
machine named X line 1000R whose build chamber size
surpasses anything that was previously known. By using
a 1 kW fibre laser system, the layer thicknesses and track
widths can be increased by several factors, which means that
productivity can be increased more than ten-fold compared with
conventional systems.
10:30–10:55 am
Development of a Lightweight Hydraulic Valve
Manifold by Selective Laser Melting Technology
Gerhard Hummel, Dipl.-Ing., MSC, Hydraulics System Engineer/
Designated Certification Specialist, Airbus Operations GmbH
Frank Schubert, Dipl.-Ing., Scientific Staff Member,
Chemnitz University of Technology
Alexander Altmann, Dipl.-Ing. (FH), R&T Project Manager,
Liebherr-Aerospace Lindenberg GmbH
This session will show the development process of a SLM valve
manifold based on Airbus A380 equipment. In consideration
of functional hydraulic schematics, installation and interface
requirements, the rearrangement of sub-components and
connector system was performed. Additionally SLM design
directives, including strategies for supporting structure and postprocessing
reduction, were developed and applied.
11:30–11:55 am
Selective Laser Sintering (SLS) of Next Gen
Unmanned Air Vehicles (UAVs)
April Cooke, Mechanical Engineer, Paramount Industries
3D Systems delivered an innovative design process and
manufacturing solution for the next generation of Small
Unmanned Air Vehicles (SUAVs). This work presents a
trade study between traditional manufacturing techniques
and Selective Laser Sintering for the fabrication of SUAVs.
The original SUAV design was an aircraft fabricated from
traditional carbon fiber composite material. This design was
adapted for rapid manufacturing and flight test comparison.
Composite materials (comprised of carbon fiber, Kevlar, and/or
fiberglass fabric and epoxy resins) were the baseline structural
technology for comparison. The design methods for SLS will be
discussed focusing on the implementation of conformal lattice
structures (CLS). Although the original air vehicle design was
well established, an equivalent rapid manufactured (RM) SLS
structure was qualified. The same control mechanisms were
34 sme.org/rapid

used in both configurations. Comparisons of weight, cost, and
flight performance were performed, and this work describes the
findings in each area.
Medical and Dental Applications
10 am–5 pm
Medical applications including dental continue to grow in use
and scope. These include, but are not limited to, prototyping,
bio-modeling/anatomical modeling and direct production of
implantable metal implants or scaffolds for tissue engineering.
10–10:55 am
Medicine Meeting AM Technology:
Close Encounters of the Third Kind?
Jules Poukens, Professor, MD, DMD, PhD,
University Hasselt Belgium
CAD/CAM and Additive Manufacturing (AM) are getting more
attention in the medical sector, especially in cranio-maxillofacial
surgery where defects of the face (e.g., absence of a nose, ear,
or eye) have an important psycho-social impact. Radiological,
optical, or laser scans of the patient are converted into a virtual
three-dimensional patient with subsequent virtual design of a
medical device or implant. AM methods enable the production
of custom implants and prosthesis in a solid or resorbable
material, or even in multiple materials. The introduction of AM
and related technologies in medicine are a breakthrough in the
treatment of very complex patient cases that were previously
untreatable. What’s more, they are reducing operating time
and patient discomfort. This progress is serving as a “stepping
stone” to the 3D printing of organs in the future in order to
improve life quality of the patient. Introduction of engineering in
medicine looks as a small step for an engineer, but represents a
giant leap in medical history.
11–11:25 am
Direct Comparison of DMLS and
EBM Ti6Al4V Performance in Vivo
Emanuele Magalini, R&D Manager, Eurocoating s.p.a.
Additive Manufacturing (AM) techniques, such as EBM and
DMLS, using Ti6Al4V powder, are suitable to produce implants
with porous surfaces named “trabecular-like” structures.
Solid part and trabecular surface are produced in the same
manufacturing step. The importance of mimicking human
trabecular structure on implant surfaces is confirmed by
investigations that showed a substantial increase in implant
fixation strength when highly complex networks are used.
Our contribution to this thesis comes through in vivo tests done
in goat model. The same trabecular structure was manufactured
using either EBM or DMLS. Specimens with different pores
and struts sizes were obtained, due to dissimilar resolution
limits existing for the two techniques. Explanations occurred at
four weeks after surgery for one group and at 15 weeks for the
second group. Each goat received EBM and DMLS specimens for
mechanical and histological analysis.
11:30–11:55 am
Additive Manufacturing for Surgical Implants:
It’s the Present and the Future
Andy Christensen, President, Medical Modeling Inc.
In the last decade since Electron Beam Melting (EBM) was
introduced it has been applied to produce real-world production
parts in the aerospace and medical device fields. In the
medical device field, EBM has been used to displace traditional
manufacturing techniques for existing products as well as enabling
production of completely new products not otherwise possible to
produce. These unique opportunities to provide value and enable
novel devices are where much of the focus will continue to be
placed. This talk will focus on how additive manufacturing is
being used today for production of implantable medical devices in
addition to where the presenter feels the market will continue to
grow over the coming years for these technologies.
1:30–1:55 pm
Using Additive Manufacturing to Produce Custom
Prosthetic Attachments for Wounded Warriors
Peter Liacouras, PhD, Director of Service, 3D Medical
Applications Center, Walter Reed National Military Medical
Center Bethesda
Kevin Wurth, Director of Operations, 3D Medical Applications
Center, Walter Reed National Military Medical Center Bethesda
The technology in the design and function of the prosthetics the
military uses to restore function and mobility to our wounded
warriors is highly advanced and unique. These typically young
6/2013 – RAPID 35

ConferenCe Details
patients are extremely active and desire to take part in numerous
complex activities such as kayaking, skiing, scuba diving,
etc. Prosthetics can accommodate, design, and manufacture
numerous devices with standard materials and limb assemblies
currently on the market to address these needs; however,
some specialty attachments need to be custom designed and
manufactured. Additive manufacturing is the most flexible and
applicable solution to aid in these limited quantity production
needs. Custom attachments are currently being manufactured at
the 3D Medical Applications Center, WRNMMCB, for a multitude
of functions such as “Shorty Feet” and “Mechanics Feet,” that
allow a bilateral amputee to walk and maneuver under cars
without attaching their full prosthetic; a “Pilot Foot” to help an
amputee continue to pilot a plane; a “Hockey Hand” to allow a
wounded warrior to play hockey with both hands on the stick; and
a “Gun Holder” to allow an amputee to hold and fire a handgun.
2–2:25 pm
Design and Fabrication of a Variable Impedance
Prosthetic Socket Through Multimaterial
3D Printing Techniques
David M. Sengeh, MS, Graduate Student, MIT Media Lab
Today, nearly 100% of amputees report some form of discomfort
in their prosthetic sockets. Our session will highlight work done
in the design and manufacture of a multimaterial 3D-printed
prosthetic socket by the Biomechatronics Group at MIT Media
Lab and Stratasys. Custom-fitted prosthetic sockets designed with
variable impedance determined by the underlying anatomy at each
node within the prosthetic socket have been manufactured and
used in lab settings. Our prototypes, which combine conventional
manufacturing processes and 3D printing, have been used outside
the lab in a recent investigation. The combination of both CAD/
CAM and conventional materials and processes gives us the best
of both worlds: structural integrity and variable impedance to
increase the comfort level of amputees.
2:30–2:55 pm
Guided Decision Making in Aortic Aneurysms Using
Patient Specific 3D Reconstructions and Printed
Models: A Case Study
Todd Pietila, B.SC., Application Engineer, Materialise USA
Objective: We demonstrate a case of a complex aortic dissection
operated 11 years ago, presented recently with a fast growing
aneurysm in the distal arch and descending aorta. Closure
was tried unsuccessfully with a small occluder. The case was
further investigated with a novel method of 3D reconstruction
and additive manufacturing. The objective of this study was to
evaluate if the patient-specific 3D reconstruction and 3D-printed
model provides information on the failure of the first intervention,
and reveals other options for treatment.
Conclusions: This novel approach of 3D reconstruction as well as
3D printing convincingly showed the failure of the first occluder
position to resolve the problem. It revealed other reentries into
the false lumen which were not visible on the normal CT scan.
Therefore, we conclude that 3D reconstruction as well as 3D
printing can help in planning and follow-up in such complex
surgical/interventional cases.
3–3:25 pm
3D Printing Advances Patient-Specific Biomedical
Engineering Modeling and Experimentation
William W. Dahl, Vice President, Marketing and Communications,
Solidscape, Inc.
David H. Frakes, PhD, Assistant Professor, Arizona State
University, School of Biological and Health Systems Engineering
John Wigand, MME, Vice President of Product Development &
Strategy, Solidscape, Inc.
Cerebral aneurysms affect 1 in 50 people and cause nearly
20,000 deaths in the United States every year. With endovascular
treatments as the standard of care for cerebral aneurysms,
anatomically correct, transparent aneurysm models for fluid
dynamic experiments are needed in improving device design and
flow knowledge. While direct-from-RP approaches to transparent
modeling have come a long way, they are currently not wellsuited
for accurate fluid dynamic experimentation. We present a
wax-based RP and lost-core methodology as an alternative that is
cost-and-time-effective in creating transparent, scale aneurysm
36 sme.org/rapid

models from actual patient anatomy. The models are created
with an interdisciplinary approach that repurposes traditional
and modern modeling techniques (e.g. lost wax castings from
3D-printed models). Wax RP, now accurate within 10 microns, is
used to create the model core, which is then translated into a
metal core via casting. The polished metal core is embedded into
an optically clear urethane block and the metal is subsequently
evacuated. In addition to flow models for experiments, providing
a surgeon with a to-scale and highly accurate representation of
patient-specific anatomy may lead to better-informed surgical
decisions. This interdisciplinary modeling leverages the latest
wax-RP technology to create accurate, scale vascular models in
a cost- and-time-effective manner.
3:30–3:55 pm
Streamlining the Biomodeling and Biomedical
Design and Development Processes
Arif Sirinterlikci, PhD, Professor of Engineering/Interim Head,
Robert Morris University
can be used to guide tissue regeneration. We have previously
demonstrated the use of a commercial continuous Digital Light
Processing (cDLP) device to prepare bone tissue engineering
implants from poly(propylene fumarate) (PPF) using one dye,
titanium dioxide, and one photo crosslinking initiator, Bis(2,4,6-
trimethylbenzoyl)-phenylphosphineoxide (BAPO), with accuracy
in the tens of microns. Higher resolution 3D printing of these
implants could be used to improve control over pore geometry
and implant resorption. We have recently determined that the
resolution of cDLP-rendered PPF implants can be increased
through the use of two dyes, titanium dioxide and oxybenzone
(2-Hydroxy-4-methoxybenzophenone), along with BAPO. It
appears that titanium dioxide alone acts to scatter, and therefore
block, incoming light. This controls resolution in the “Z”
direction. Oxybenzone appears to absorb, and therefore block,
the scattering of light laterally, thereby controlling resolution in
the “X” and “Y” directions. These two dyes also appear to allow
delivery of more light energy, resulting in fuller crosslinking and
improved post-fabrication handling of this soft implant material.
The main objective of this study is to present case studies which
are being utilized in streamlining the biomodeling and consequent
prosthetics design and development processes. The presenters
will move from medical imaging into CAD design environments
by explaining each step of the processes. Mimics, 3-Matic,
and Geomagic Studio tools will be included in their respective
steps. The presentation will conclude with a research section,
outlining the possibility of employing these processes in design,
development, and fabrication of orthoses such as cranial helmets,
braces and many more. The role of RP Technologies will help
finalize the argument for the customized orthotics development
and manufacturing.
4–4:25 pm
Continuous Digital Light Processing (cDLP) for the
Highly Accurate 3D Printing of Tissue Engineering
Bone Implants
David Dean, PhD, Associate Professor,
Case Western Reserve University
4:30–4:55 pm
Customized Surgical Instrument for Maxillofacial
Surgery by SLM: Case Study, Process Steps,
Powder Specifications
Adeline Riou, Marketing Deputy Director, ERASTEEL
Fermin Garciandia, Senior Researcher,
Materials & Processes Area, IK4-LORTEK
Jaime Ochoa, Researcher,
Materials & Processes Area, IK4-LORTEK
This presentation also highlights the benefits of technical
cooperation between surgeons, users of additive manufacturing
equipment and metallic powder producers. The paper is
coauthored by IK4-Lortek, an R&D center with a research line
focused on laser additive manufacturing (including both SLM
and metal deposition technologies); Erasteel, producer of tailor
made fine metal powders for additive manufacturing by VIM gas
atomization; and has enjoyed the cooperation of Basurto Hospital.
Highly accurate three-dimensional (3D) printing (i.e., additive
manufacturing) of resorbable, internally porous, polymer
implants could prove useful for tissue engineering applications.
The geometry of the internal pore spaces of these implants
6/2013 – RAPID 37

ConferenCe Details
Additive Manufacturing Applications I
10 am–Noon
Presentations detailing case studies and research and
development activities that continue to advance the applications
of additive manufacturing and 3D printing.
10–10:25 am
IT Enabled Technologies Disrupt Manufacturing
Irene J. Petrick, PhD, Professor, Penn State University
In the past several decades, manufacturers have seen
disruptions coming from competing production technologies
and from low cost global competitors. Today and into the future,
the disruptions are coming from sources many don’t even see
coming. Specifically, the future manufacturing landscape will
be enabled by developments in information technology. Access
to high performance computing at a cost competitive rate will
level the playing field for advanced modeling, analytics and
simulation. When combined with developments in 3D printing/
additive manufacturing, one-off, highly customized production
will compete with mass production. Current manufacturers will
need to learn how these 3D printing/additive manufacturing
technologies can coexist alongside their more traditional
processes. As these tools become simpler to use, Internetsavvy
hobbyists and do-it-yourselfers will effectively be able
to challenge very established firms. Cloud supported services
will be a viable replacement for extensive enterprise resource
planning and customer relationship management systems, and
will provide the real-time visibility into the supply chain and
production environment that customers will demand. In the
coming decade, the installed base that has been a barrier to
entry for new firms will become a barrier to change for many
established manufacturers.
ceramic part, both before and after firing the material. Small
quantity orders are often extremely expensive and accompanied
by long lead times which can delay projects relying on the
properties of ceramic components.
3D printing not only allows for faster time to market, but also
allows for more iterations during the design process, resulting
in a better end product. Materials used in rapid ceramics range
from less-hard alumina ceramics (aluminum oxide filler) to very
hard and abrasion-resistant zirconia ceramics (zirconium silicate
filler). These ceramics can withstand between 2800ºF (1538ºC)
and 3200ºF (1760ºC) working temperatures, and have a dielectric
strength of 150 volts per mil. The alumina ceramic material
is extremely abrasion-resistant, corrosion-resistant, and has
excellent mechanical performance.
11–11:25 am
Unisource Engineering Solutions Uses Mcor
3D Printing to Make More Realistic Packaging
Prototypes
Gary Fudge, Director, Americas, Mcor Technologies Ltd
Unisource Engineered Solutions (UES) combines science and art
to create high-impact product-packaging solutions.
Challenge: Generating more sales and satisfaction with more
realistic packaging prototypes. A staple in modern packaging
design is thin-walled molded pulp. UES makes similar packaging
from bamboo pulp and sugar cane residue called bagasse.
Biopulp packaging elements include a hollow for each packaged
part. Until recently, it’s been nearly impossible to provide the
customer with a prototype whose texture better resembles the
final product.
10:30–10:55 am
Breaking The Mold—3D Printing Engineering
Grade Ceramic Materials
Benjamin Becker, BS, Managing Director, HotEnd Works, LLC
UES had instead been settling for plastic prototypes which
are fine for form and fit, but the look and feel is nothing like
thin-walled molded pulp, which has greatly impeded sales and
negatively impacted customer satisfaction.
Expensive post processing of the ceramics is often required
either to create intended geometries that could not be created in
the initial machining state, or to bring the part within the design’s
tolerance. Investment in carbide or diamond tooling and fixturing
is often necessary in order to create certain features on the
Strategy: 3D printing prototypes with paper.
38 sme.org/rapid

11:30–11:55 am
Evaluating Your 3D Printing Options:
Advice from the Experts
Todd A. Grimm, President, T.A. Grimm & Associates
Kevin L. Ayers, BS, Mechanical Engineer, FBI
This presentation will guide the attendee on how best to obtain
the right technology to meet their needs. We will start by
going through a checklist identifying their organization's key
requirements for the system.
• How to thoroughly investigate all 3D printer options
• How to best reach out to salespeople, users and
industry experts
• Explore the common pitfalls in the industry
• Learn how to best hedge your bet before, during,
and after the selection
Creative Uses for Art, Architecture and More
10–11:55 am
New materials are contributing to thinking outside the box for
product designers. This session will present applications for
additive manufacturing/3D printing used in art, jewelry making,
fashion, entertainment and the emerging maker community.
10:30–10:55 am
Making It Personal
Sean Wise, President, RepliForm Inc.
Evaluate the suitability of several additive manufacturing
methods to make personal figurines or statuettes that would
be of sufficient quality to display in the formal living spaces in a
consumer’s home or office, just as portraits are displayed now.
The figurine geometric data was submitted to several traditional
service bureaus and equipment manufacturers along with several
consumer-level 3D printer manufacturers with the instructions
to give us the best quality output the machines are capable of.
These were returned to us for evaluation and application of a
copper electroplated coating. This presentation will review the
quality vs. costs to produce a 3D-printed resin figurine on the
systems that were tested, along with the suitability of each for
plating. We will look at this trade-off for printing of individual
pieces on personal printers and industrial additive manufacturing
systems as well as the cost of full trays or vats of unique parts
on the industrial systems. This was done since a combination of
personal and industrial printers might allow a studio doing the 3D
data capture a reasonable way of handling peak and slack times
for the finished items that might be given as gifts.
10–10:25 am
The Factory 2.0: The RAPIDLY Evolving Relationship
Between Art and Additive Manufacturing
Murray Moss, Curator and Creative Director, Moss Bureau
This presentation will illuminate the RAPIDly evolving relationship
between art and additive manufacturing. The interactive
installation at the Warhol Museum will show the intersection
of Andy’s Warhol’s now-iconic innovations in art with the new
possibilities today.
The presentation will also focus on innovations which are
changing how art is conceived and made by highlighting
proprietary Mammoth Stereolithography technology. The
Mammoth printers have made previously unrealizable, mammoth
works of art a reality.
11–11:25 am
Merging Digital and Physical Processes in
Architectural Design and Fabrication
Madeline Gannon, Adjunct Instructor, School of Architecture,
Carnegie Mellon University
There is still a palpable disconnect between how architecture is
designed in the digital realm, and how it is realized in the physical
realm. A number of factors contribute to this gap, including a
virtual environment’s infinite scale, its autonomy from a tangible
context, and its lack of physical materiality. This presentation
addresses such issues through custom vision-based modeling
software that uses a 3D scanning/sensing/printing workflow to
merge digital processes in architectural design with physical
processes in fabrication. The application internalizes three layers
of physical information to simultaneously influence the digital
design. The first layer is a physical context that is 3D scanned
as the base geometry from which to design. The second layer
uses a depth camera to sense a designer’s hand gestures, and
brings it into the virtual environment as a 3D controller. The third
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ConferenCe Details
layer encodes the material limits of the output device (an FDM 3D
printer) into a design of a digital 3D module. The user can then
gesture with his hand to digitally model a sculptural form, which
is also instantly optimized for 3D printing. Potential applications of
this 3D scanning/sensing/printing approach have been explored
at the scale of the building, through architectural ornament,
and at the scale of the body, through wearable armature. This
interface between digital design and physical production
demonstrates how designers can rapidly generate intricate
and elegant digital forms that are both grounded in a physical
context and are instantly available to be made tangible through
3D printing.
11:30–11:55 am
Precious Metals in Additive Manufacturing
Joseph Strauss, PhD, Engineer/President, HJE Company Inc.
There is significant interest in additive manufacturing of precious
metals in the jewelry, watch, and dental industries. Although
direct manufacture of functional metal parts is practiced with
traditional engineering materials (steels, Ti-alloys, Co-Cr, etc.)
direct manufacture of precious metal alloys has several unique
requirements and challenges. For example: the part’s surface
finish is more critical, machine size and type can strongly affect
process economics, and the powder supply chain is in its
infancy. This presentation will discuss the application of additive
manufacturing to precious metals with respect to technical,
economic, and infrastructure aspects and also report on current
activity in additive manufacturing of precious metals.
Final Part Production
1:30–5 pm
Additive Manufacturing is not just for prototyping. This session
will detail applications where the additive process is used to
save time and expense in final part production.
1:30–1:55 pm
A Case Study in the Use of Additive Manufacturing
as a Viable Production Process
David K. Leigh, President, Harvest Technologies Inc.
Ben Fulcher, Engineer, Harvest Technologies Inc.
manufacture, minimal geometrical limitations, and the lack of
an initial tooling investment (as compared to injection molding).
Many of the AM technologies have been built around prototyping
and concept model criteria and do not lend themselves to
functional parts to be used in “end-use” applications. However,
as the knowledge and adoption of additive manufacturing
grows, the market for additively manufactured end-use parts
grows with it. Powder-bed fusion (PBF) processes, such as laser
sintering (LS) of polymers and selective laser melting (SLM) of
metals, have been increasingly used in recent years as a bridge
to traditional production processes as well as the production
process of choice. The ability to consistently produce quality
parts within dimensional and mechanical specifications has been
a key to this progression and is necessary for its future. Harvest
Technologies (Harvest), an AM production company of LS and
stereolithography (SLA), continues to pioneer efforts to make
LS relevant for the sustained production of end-use parts. This
presentation will be a case study of the production and quality
processes necessary to maintain production within the additive
manufacturing industry.
2–2:25 pm
Battlefield Printing of Surgical Instruments
by Fused Deposition Modeling
Shayne A. Kondor, Medical Modeling Engineer,
Naval Postgraduate Dental School
Limited availability of sterile surgical instruments in austere
and combat environments is a challenge. Logistic and supply
constraints limit the quantity and variety of surgical instruments
available in the field, and sterilization equipment is often not
available to support the instruments on hand. Fused Deposition
Modeling (FDM) presents a solution to these problems: durable,
biocompatible plastic resins can be printed by FDM into any shape,
and emerge sterile from the process. This concept was explored
by the Defense Advanced Research Projects Agency (DARPA)
Service Chiefs Fellowship Program as a 90-day proof of concept.
Over a period of less than three months, the team developed and
demonstrated the ability to produce sterile surgical instruments in a
field setting using an FDM additive manufacturing device.
Additive manufacturing (AM) of plastics naturally lends itself
to the prototyping business model due to the ability for fast
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2:30–2:55 pm
Additive Manufactured Modular Telescoping
Wing Unmanned Aerial Vehicle
Michael Stern, Rapid Prototyping Engineer, MIT Lincoln Laboratory
Eli Cohen, UAV Test Engineer, MIT Lincoln Laboratory
We present a low-cost, highly flexible and modular Unmanned
Aerial Vehicle (UAV) for atmospheric sensing. A novel
aerodynamic design was realized with a lightweight, efficient
mechanical structure designed for and fabricated with additive
manufacturing (AM) to meet performance requirements. The
aerodynamic design features telescoping wings to permit both
dash and loiter flight depending on the exposed wing area
and airfoil. The aircraft structure is primarily Fused Deposition
Modeling (FDM) ABS-M30 with supplemental carbon fiber. The
total weight of the aircraft was seven pounds with a wing span
of 80". We designed the structure to be easily assembled using
only standard hand tools. The modular design permits rapid
reconfiguration of the aircraft and the ability to swap payloads
while simplifying replacement of damaged parts, even in the field.
Focus on frangible design prevents widespread damage and
minimizes rebuild in the case of failure. We completed several
test flights demonstrating the structural integrity of the AM parts
and the success of the overall design.
This work is sponsored by the Air Force under Air Force contract
number FA8721-05-C-0002. The opinions, interpretations,
recommendations, and conclusions are those of the authors and
are not necessarily endorsed by the United States Government.
3–3:25 pm
Global Advances in Metal Additive Manufacturing
for Final Part Production
Tim Caffrey, BS, Associate Consultant, Wohlers Associates
Applications for metal parts built by additive manufacturing
have developed quickly in the decade or so since metal AM was
introduced. The technology for the production of parts that go
into final products is also growing at a fast pace. Caffrey will
discuss materials, processes, systems, and current applications
for final part production in the aerospace, medical, dental, and
jewelry industries around the world. The presentation will also
cover the current and future challenges of manufacturing with
metal AM processes.
3:30–3:55 pm
Additive Manufacturing—A Critical Review
Walter J. McGee, FIAE, Sr. Design Check Engineer II,
Raytheon Space & Airborne Systems
In evaluating the potential of AM and MBD as the wave of the
future, it is vital that adequate attention be given to both the
benefits and challenges these technologies present. These
technologies offer the possibility of paperless engineering and
more cost effective manufacturing of complex or small quantity
parts. However, along with the significant savings potential,
these technologies raise some important questions. For example,
are new methods/equipment needed to accurately measure the
size and shape of more complex geometries? What changes are
needed to qualify AM materials and processes to allow broader
use in prime hardware? How should paperless companies
prepare for a natural or terrorist event that could destroy
electronic technical data?
This report will consider a few of the questions that should
be asked when weighing the costs/benefits of adopting these
new technologies.
4–4:25 pm
Sustainable Cars and the Future of Manufacturing
Jim Kor, P.Eng., President, KOR EcoLogic
For URBEE 2, KOR EcoLogic has made a mental leap. They are now
designing the car so that the major body and interior parts (about
40 to 50 parts in total) MUST be made by the 3D printing process.
No other process will be able to make parts as complicated as
they plan to design. This is quite different than rapid prototyping
a few parts. This designing exclusively for 3D printers has
been termed Digital Manufacturing. KOR EcoLogic expects to
manufacture these parts in a “factory of the future” that houses
many 3D printers, all mass producing production parts.
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4:30–4:55 pm
Panel Presentation
Moderator: Ryan Larson, Nike Inc.
Panel Participants:
Dave Abbott, GE Aviation
Chris Gravelle, Bell Helicopter
Garrett Grindle, Human Engineering and Research Laboratories
at VA Pittsburgh
Jim Kor, KOR EcoLogic
This panel is composed of experienced practitioners and users of
additive manufacturing to build parts. The discussion will include
benefits and challenges of bringing additive manufacturing
into production, printing final parts, and how the finished parts
contribute to lower labor costs, speed up assembly times, and
increase final product quality.
Additive Manufacturing Research
1:30–5 pm
Learn about the efforts to advance the uses of additive
manufacturing technologies. A variety of processes and
materials will be covered.
1:30–1:55 pm
Laser Additive Manufacturing of Pure Copper
Federico Sciammarella, PhD, Assistant Professor,
Northern Illinois University
The deposition of pure Copper via additive manufacturing poses
some difficult issues. This presentation highlights the additive
manufacturing (via LENS) work being done in parallel by the Laser
Materials processing group at the National Laser Centre and the
Macro/Micro Manufacturing Lab at Northern Illinois University.
At this stage, deposition of higher than 2 to 6 mm was not possible
due to the high conductivity of the first few deposited layers of
Cu. The high reflectivity also makes it difficult to build beyond this
threshold level of layers as most of the light is reflected back,
thus reducing the amount of energy absorbed by the melt pool.
Some further efforts were carried out at NIU which involved preheating
the substrate prior to deposition, it is anticipated that this
may increase the deposition amount.
2–2:25 pm
Powder-Based Electron Beam Additive
Manufacturing—Process Modeling with
Applications to Novel Overhang Support Designs
Kevin Chou, PE, ASME Fellow, Professor, University of Alabama
This presentation will discuss the powder-based EBAM
technology. In particular, modeling of the EBAM process physics,
by finite element (FE) analysis, will be addressed. The key points
of the model will be elucidated using different examples, and
process improvements derived from FE simulations/analyses will
be demonstrated. One improvement is novel overhang support
structure designs, which will eliminate the need of mechanical
ways for support removals, and thus, simplify post-processing
and enhance EBAM performance. The study demonstrates
the powerful potential of FE modeling in studying the EBAM
fundamentals and in capturing the complexity of the process,
which in turn helps understand and advance metal-based rapid
manufacturing technologies.
2:30–2:55 pm
Modeling and Validation of Residual Stress and
Distortion in Direct Metal Deposition Processes
Michael F. Gouge, Graduate Research Assistant,
Penn State University
Direct metal deposition processes are becoming increasingly
important in the repair of high-value components. Unfortunately,
the high temperature gradients experienced by the deposited
material, as well as the substrate material during processing, lead
to the formation of high levels of residual stress and distortion.
In this work, thermo-mechanical finite element analysis of the
process is performed using a moving heat source model for the
multilayer laser cladding of Inconel® 625 at a laser power of
2500 W on 12.5-mm thick plates. Both powder and wire-fed metal
deposition methods are evaluated with depositions paths in both
longitudinal and transverse orientations. In order to validate
the modeling results, in-situ temperature and deformation
measurements are performed using pre-placed thermocouples
and by fixturing the plate on one end and measuring deflection on
the opposite end. These results are validated using pre- and postprocess
coordinate measurement machine (CMM) measurements
at several points on each plate and residual stress measurements
made using the blind hole drilling (BHD) method. Both layer-based
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and heat source position-based element activation methods are
evaluated, providing baseline data for the eventual validation of
these models to predict distortion and residual stress during laser
cladding repair processes.
3–3:25 pm
Designing and Building Open Source Rapid
Prototyping Machines
Arif Sirinterlikci, PhD, Professor of Engineering/Interim Head,
Robert Morris University
Robert Morris University (RMU) Manufacturing Engineering
Laboratories are equipped with SLA, FDM, and ProMetal 3D
printing systems. After working on biomodeling, rapid tooling and
small metal parts fabrication projects, the RMU RP/AM Group is
capturing one of the most recent and interesting developments
in the area - open source and rep-rap systems. After building
two fused filament machines and improving their accuracies, the
group has recently completed another machine based on digital
light processing (DLP) curing of polymers. This machine will be
used in testing of different materials including composites. The
results will also lead to the development of a novel process and
its associated hardware and software. Details of the test results
and machines will be a part of the presentation showing concrete
evidence of the work.
3:30–3:55 pm
Additive Manufacturing’s Role in the Development
of Safe, Compact, Integrated Fluid Power Systems
Jonathon E. Slightam, Graduate Research Assistant, Rapid
Prototyping Research, Milwaukee School of Engineering
The Milwaukee School of Engineering (MSOE) is presently
involved in the collaborative effort on the NSF funded Engineering
Research Center for Compact and Efficient Fluid Power
(ERCCEFP) Project 2G with Vanderbilt University and Georgia
Tech. Project 2G: Fluid Power Surgery and Rehabilitation Via
Compact Integrated Systems is aimed at breaking major technical
barriers related to compact integrated systems (by designing
systems where valves, cylinders, and sensors are not separate
entities and can be manufactured simultaneously) and making
fluid power systems safe and easy to use. Fully exploiting fluid
power as a compact, efficient, and effective source of energy
transmission is a vision of the ERCCEFP and MSOE seeks to
exploit this vision with additive manufacturing. MSOE has sought
to accomplish this by improving the understanding of additive
technologies for applications in fluid power to develop more
compact and inherently safe devices. Through MSOE’s efforts,
novel actuators, mechanisms, non-assembly fluid power robots
were developed. Modeling of additively manufactured fluidic
bellows and comparison to other actuation technologies was
a product of MSOE’s research to illustrate the feasibility of
additive manufacturing in fluid power robotic surgery. Prior work,
collaborative efforts, future research and potential applications of
MSOE’s efforts are discussed.
4–4:25 pm
Laser Additive Manufacturing
for Blow Mold Applications
Lijue Xue, PhD, Senior Research Officer,
National Research Council Canada
Tony Paget, CEO, Garrtech Inc.
Blow molding is a manufacturing process by which hollow plastic
bottles or parts are produced. Aluminum alloys are typically used
to make blow molds because of their good machining ability and
thermal conductivity. However, aluminum alloys have relatively
inferior wear resistance. During the blow molding operation,
the parting lines or pinch-off areas of the aluminum molds are
subjected to severe wear as a result of compression and cyclic
impact. In order to extend mold life, inserts made of hard and
tough metals (typically, beryllium-copper) are usually used at
the pinch-off and other heavy wear areas, which significantly
increases manufacturing cost and time. This presentation will
report our development work on laser cladding of wear resistant
materials to replace toxic beryllium-copper inserts, including
property evaluation and durability study. Preliminary blow-mold
production testing has demonstrated that laser-clad pinch-off
shows much longer life than the typical beryllium-copper insert,
while it also provides additional benefits such as improved
productivity and cosmetic improvement of the produced bottles.
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4:30–4:55 pm
Process Mapping Methods for Integrated Control
of Melt Pool Geometry and Microstructure in Direct
Metal Additive Manufacturing
Jack Beuth, PhD, Professor, Department of Mechanical Engineering,
Carnegie Mellon University
Control of melt pool geometry and microstructure are critical
concerns for direct metal additive manufacturing process
qualification within the aerospace and other industries. This work
demonstrates a P-V Process Map TM approach for mapping the
role of major process variables in determining: 1) key melt pool
dimensions, and 2) microstructural features. Combining these
process maps further leads to an approach for indirect control
of microstructure through direct control of melt pool geometry.
In this talk, methods are applied to wire-feed electron beam
AM processes. Modeling results over a wide range of process
variables are presented to illustrate the approach for deposits of Ti-
6Al-4V. Experimental results are presented that are consistent with
the model predictions. By linking microstructure control to melt
pool geometry, which can be monitored in-situ, the number of tests
and microstructural examinations needed for process qualification
can be significantly reduced. These methods can also be the basis
for advanced approaches to thermal imaging feedback control.
3D Imaging & Scanning
1:30–5 pm
This session will cover applications that make use of scanning
technologies for reverse engineering, analysis and inspection
that contribute to the manufacturing of products using additive
and 3D printing processes.
1:30–1:55 pm
Preserving the Past, Developing the Future—
A Collaboration of Emerging Technologies
Vince Anewenter, Manager of Operations,
Milwaukee School of Engineering
District of South Carolina. Vince Anewenter, RPC manager of
operations, used 3D laser scanning to create an exact digital
copy of an original face jug. Using the digital file, Anewenter and
biomedical engineering student Nora Huang worked with Brian
Gillis to convert the model into a functional time capsule. MSOE
used a variety of specialized CAD softwares to manipulate the
original scan file into the final functional time capsule design.
Using Selective Laser Sintering (SLS) technology the RPC
additively manufactured the actual time capsule. The nylon SLS
model was then coated with .005 nickel by RePliForm Inc. in order
to provide the physical and aesthetic properties required.
2–2:25 pm
Structured Light 3D Scanning Fundamentals
Thomas Tong, President, 3D3 Solutions
We plan to cover a range of topics around the process of
performing structured light 3D scanning. We’ll start with laser
vs. whitelight/structured light since most people are familiar with
how laser scanners work but not how structured light scanners
work. Next, we will discuss some of the perception versus the
reality of the current state in the 3D scanning process. We
will also cover the 3D scanning workflow in depth, specifically
part mounting and part preparation, alignment strategies, 3D
scanning, and how to do scan data cleanup and analysis.
2:30–2:55 pm
Wearable Technologies Benefit From 3D Imaging
Aaron Trocola, BS, Founder, Threeform Fashion
3D scanning and 3D printing systems have been used in
combination in medical, industrial and scientific, and–more
recently–in functional apparel and fashion. Of course it is
also being used heavily in prototyping and in some cases
producing the body-interface portion of wearable products and
technologies. This paper will focus on consumer applications and
explain why we see the wearable space is ready for innovation.
MSOE’s Rapid Prototyping Center helped the Chipstone
Foundation and commissioned artist, Brian Gillis, to create a time
capsule in the image of a historical artifact which will serve as a
center piece to a traveling sculpture exhibit. The exhibit, “Face
Jugs: Art and Ritual in 19th-Century South Carolina,” features
face jug vessels that were created by slaves in the Edgefield
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3–3:25 pm
Determination of a Scaling Factor for
Use in an Electron Beam Melting Additive
Manufacturing Machine
Andrew Klarner, Student, Ohio State University
Paris Cornwell, Scientific Associate/Student,
Oak Ridge National Lab
To improve the tolerances of components produced by the
Arcam A2 additive manufacturing system a scaling factor is
used. A FARO laser metrology unit was used to measure the
dimensions of the components produced by the Arcam A2
system. The measured dimensions of the Acam A2-produced
parts were compared to the original CAD drawing by using
Geomagic parametric modeling software. It was found that
the dimensions of Arcam A2-produced parts varied with
build orientation and possibly other factors. Determining an
optimized scaling factor has great utility for improving parts
produced by additive manufacturing.
3:30–3:55 pm
Tessa’s Eyes—An Effort to Help Protect
a Little Girl’s Eyes
Jason Reznar, Senior Product Development Engineer,
Rayce Americas
Giles Gaskell, Sales Manager, Wenzel America
Moebius Syndrome is a rare neurological disorder that is present
at birth. It primarily affects the 6th and 7th cranial nerves, leaving
those with the condition unable to move their faces. They can’t
smile, frown, suck, grimace or blink their eyes and typically can’t
move their eyes laterally. Tessa, since birth, has not been able
to blink or close her eyes. Her family has been putting “shields”
on her eyeglasses to protect her eyes. The shields provide a
moisture barrier to help keep her eyes protected and help keep
them from drying out. These shields were very laborious and a
daily activity—they often did not last a full day. After meeting
Tessa, we knew that we could provide a solid solution utilizing
our additive manufacturing machine along with 3D scanning.
We partnered up with Giles Gaskell at Wenzel America and it
was determined that we could scan Tessa’s face along with her
glasses—utilizing line scanning as well as CT scanning. From this
data we were able to extract models to use in our CAD software
to start modeling the new shields that would be permanently
attached to her glasses. Utilizing our Objet Connex 500, we were
able to provide a rigid, clear material that will match Tessa’s face
and glasses exactly. Not only does this solution protect her eyes
greatly, they eliminate the daily need to create shields.
4–4:25 pm
Optical Inspecting via Structured Light Scanning—
KNOW What You Made and Prove It!
Tony DeCarmine, Technical Director,
Oxford Performance Materials (OPM)
Additive manufacturing processes enable the creation of detailed,
complex structures. While this is wonderful, it creates difficulty
in inspecting such parts. Conventional approaches, including
calipering and shadow graphing, are easily defeated by features
simple to create via additive manufacturing processes. structured
light scanning (aka white light) enables inspection of whole part
surfaces. The product is a surface map, readily comparable to the
original geometry file. The SLS process is substantially faster than
either CMM or laser systems. Accuracy is more than adequate
to inspect parts with manufacturing precision typical of additive
processes. Case studies will demonstrate the virtues.
4:30–4:55 pm
The Fastest Path from Scan to CAD
Kevin Scofield, Senior Product Manager, Geomagic
Bill Greene, Founder/Vice President of Business Development,
Level 3 Inspection
This presentation will allow everyone to understand how
Geomagic Spark has turned the world of 3D scanning into CAD
design on its head. See user examples of re-engineered parts and
assemblies, created directly from a scan into a solid model with a
few clicks of the mouse; see how the power of dimension-driven
design and editing, assembly modeling, and use in integrated
CAE, CAM and rendering applications, transforms the world
of scanning and point cloud processing; and understand how
Geomagic Spark can fit perfectly with your existing CAD and
engineering workflows.
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Wednesday, June 12
Additive Manufacturing Applications II
10 am–Noon
Presentations, detailing case studies and research and
development activities, that continue to advance the
applications of additive manufacturing and 3D printing.
10–10:25 am
Case Study: Gas Ejector Nozzle Made
by Metal Laser Sintering
Shane Collins, Director, Business Development,
Oxford Performance Materials
Metal laser sintering (MLS), known by the trade names
DMLS and SLM, is used in demanding applications such as
surgical instruments, medical implants, jet turbine engines
and commercial aviation. Components made with MLS have
been shown by the University of Louisville and others to be
fully dense with limited porosity. This case study reports on the
use of MLS to develop a critical component for a gas ejector
nozzle requiring fine features, smooth surface finish and high
performance material properties. Through collaborative process
optimization, the challenge was met, and production-quality
nozzles were produced.
10:30–10:55 am
Metal Laser Sintering System Comparison, Product
Quality and Material Properties
Alex Fima, BS, President, Directed Manufacturing Inc.
Metal additive manufacturing, laser powder bed process, is
becoming an established technology for final part production in
diverse industries worldwide with applications from aerospace
to semiconductor. Directed Manufacturing will review the
capabilities of its current EOS and Renishaw metal laser
sintering equipment for production applications as well as
provide a material properties overview. Build speed, part quality,
cost of operations, including cover gas and consumables, and
overall productivity will be compared. Attendees will discover
the advantages of direct metal laser sintering (DMLS) and
selective laser melting (SLM) systems in a presentation that is
directly for anyone evaluating production capabilities of powder
bed metals process systems.
11–11:25 am
Conformal Cooling
Brandy Badami, Additive Manufacturing Account Manager,
Linear Mold & Engineering
Steve Spaleny, Director of Sales & Program Management,
Linear Mold & Engineering
By getting water into tight spots, we drastically improve part
quality. Using conventional methods you have to drill straight
water lines, and the intersection of two straight-drilled water
lines creates a low-turbulence area where sediment may build
up. With DMLS, Linear can design complex water lines that
eliminate these areas. Linear recently added Moldex 3D CAE
software with the FEA Interface, which can evaluate temperature
distribution. This provides in-depth injection molding simulation
to maximize the advantages of conformal cooling in the injection
molding process. The software will also be able to predict areas
in the mold that may incur hot spots, and can generate mold
bases with complex cooling channels automatically.
11:30–11:55 am
Metal Additive Manufacturing Goes Bigger
and Faster to Meet the Manufacturing Challenges
of Tomorrow!
Stefan Ritt, Export Sales and Marketing Manager,
SLM Solutions GmbH
Due to several requests from industry partners, a project got
started to design and produce a metal-AM machine which
incorporates the industrial requirements of build volume and
size and build speed and accuracy. This presentation will
highlight the demanding concept and design of a large volume
metal-AM machine operated by four high power multi-lasers
to achieve at least five times build speed compared with
today’s standard DMLS equipment to bring it much closer to
performance of existing production technologies. Reference
will be made to existing case studies and applications from
several industries and key players such as GE, Boeing, BMW,
Siemens and others. The audience will gain information
and knowledge of how to implement metal-AM not only into
high-profile and high-tech industries, but also for everyday
consumer items to bring back domestic workforce on top of
the latest technological and industrial standards into the US
and also take advantage of the benefits of powder-based
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manufacturing. The presentation will connect the present
NAMII-initiative by the US president with the technological
state-of-the-art development which will be an opportunity for
future domestic manufacturing in the US.
Casting
10 am–3:30 pm
This session will focus on applications used in metal casting,
investment casting, lost foam casting including considerations
for tooling, and material process. The morning session is a
workshop presented by the American Foundry Society.
10 am–Noon
Integrating Design Efficiency with Additive
Manufacturing to Improve Time to Market Seminar
Hosted by the American Foundry Society (AFS), this seminar
provides you with an interactive overview of various metalcasting
processes and alloys so that you can make better design
and sourcing decisions for your engineered cast components.
The application of adaptive manufacturing and rapid prototyping
technology to assist in reducing the time and cost to develop new
component designs, and also examples of conversions from other
manufacturing processes will be discussed. An informed designer
and purchaser who understands how the proper material/process
marriage can unleash the power of metal-casting will be better
equipped to create the most cost-effective product.
1–1:25 pm
Magnesium Prototypes Now
Jack Ziemba, CEO, Aristo-Cast/MagnesiumSolutions
Starting in 2001, Aristo-Cast/MagnesiumSolutions took on the
challenge of reducing the time it took to produce magnesium
prototypes using the investment casting process. Reduction
of time required to provide magnesium die-cast prototypes is
of extreme importance in allowing validation of the parts prior
to construction of costly die-cast tooling. The combination
of additive manufacturing of patterns and the ability to cast
magnesium in a fused silica shell is the method that creates
prototype parts, quickly and accurately representing the
physical attributes of the finished product. This presentation
will demonstrate how our magnesium casting process allowed
the TRICO Windshield Wiper Motor to be validated quickly,
accurately, and at a fraction of the cost of the normal methods
in use today.
1:30–1:55 pm
Light Cured 3D Sand for Rapid Casting Technology
Sam N. Ramrattan, PhD, Professor, Western Michigan University
3D printing provides the flexibility and ease of reproducing the
sand mold directly from CAD models. This eliminates the laborious
pattern making steps, thus reducing total time for prototyping.
Where 3D printing provides advantages of minimal processing
steps, higher precision, and the capability to produce complex
shaped sand molds, it simultaneously possesses some limitations
and concerns related to throughput, safety and logistics.
This study proposes an alternate methodology of developing
3D-cured sand molds by introducing a hybrid rapid prototyping
approach to overcome the limitations observed using
conventional 3D printing techniques. Resin-coated sand particles
can be bonded layer-by-layer after being exposed to a high
intensity pulsed light source which raises the layer temperatures
to a desired range for curing, followed by precision machining
to obtain complex shapes. Hybrid rapid prototyping techniques
have been employed in the past, however, the methodology of
developing sand molds by integration of photonic curing and
the idea of the use of the proposed compatible materials for this
process is fairly new. The purpose of this study is to characterize
the post-cured molding materials with tests designed to measure
the physical, mechanical and thermo-mechanical properties as
required for castability.
2–2:25 pm
Case Study: Creating a Large Prototype Pump
Impeller Using a QuickCast Pattern
Thomas J. Mueller, Director, Business Development, 3D Systems
TechCast LLC is a leading supplier of large pump impellers
and has been a pioneer in the use of direct patterns to create
quick, production quality impellers for their customers’ product
development efforts. Last year, they worked with 3D Systems
to develop a detailed case study which compared the cost and
timing of creating an impeller using a QuickCast pattern with one
created with a molded wax pattern. In addition, they compared
the dimensional accuracy, surface roughness and surface quality
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ConferenCe Details
of the two castings. The case study was done on an impeller that
is currently in production so tooling costs and lead times, as well
as actual production costs and times, were known. The resulting
data serves to provide the most accurate measure-to-date of the
benefit of the process as measured both in dollars and in time.
2:30–2:55 pm
Utilize Ancient Casting Techniques
and 3D Printing Technology to Accelerate
Direct Manufacturing Processes
John Wigand, MME, Vice President of Product Development
& Strategy, Solidscape Inc.
Emily Berg, CAM Administrator/Production Specialist/
Quality Control Specialist, Casting House
Justin Ryan, BA, Graduate Research Associate,
Arizona State University
leverages the ancient art and precision of lost wax casting
with the latest advancements in CAD/CAM design to solve
complex geometry modeling challenges in RP and direct
manufacturing processes. With fewer, if any, constraints on
model complexity—3D printing technology and lost wax or
investment casting can combine individual pieces into one
complex—even moveable—part, thus eliminating multiple
assembly steps and points of failure. Our presentation will further
explore how—for applications such as custom jewelry and even
patient-specific body parts or vascular models—high-precision
3D printing coupled with lost wax casting have become creative
manufacturing tools and research game-changers.
From small precision parts through exquisite custom jewelry
and even patient-specific biomedical models, 3D printing now
48 sme.org/rapid

3-3:25 pm
Using Additive Manufacturing
to Enhance Prototype Castings
Dave Rittmeyer, CAD Specialist/Pattern Maker, Hoosier Pattern
Product Design Considerations
Using Additive Manufacturing
10 am–3:30 pm
Additive manufacturing technologies are removing many of the
manufacturing restrictions that have compromised a designer’s
ability to make the product they imagined. Learn about new
product designs and designers who are blowing away old
“subtraction” thinking.
10–10:25 am
3D Printing’s Role in Product Development:
CaliBowl Case Study
Rich Stump, Principal, FATHOM
This presentation will provide a brief history of the product and
how 3D printing was instrumental in bringing the product to
market. Elaboration will be included on how the Objet 3D printer’s
high resolution, variety of materials, and speed affected the
development process. Related technologies will be discussed
such as 3D-printed injection mold tooling and how they will
contribute to manufacturing revolution. Also there will be
discussion on how 3D printing can help support manufacturing
jobs in the US and reduce the carbon footprint. In addition to the
current buzz surrounding the 3D printing industry, the case study
product is an award-winning, simple but revolutionary design that
many people can relate to.
10:30–10:55 am
A Process Workflow for Designing
Finished Parts for Additive Manufacturing
Matt T. Samperi, Research Assistant, Applied Research Lab,
Penn State University
Timothy W. Simpson, PhD, Professor of Mechanical & Industrial
Engineering, Penn State University
Sanjay B. Joshi, PhD, Professor of Industrial Engineering,
Penn State University
This presentation will provide a complete description of the
process workflow from a concept design to a finished part
using additive manufacturing. It will describe what options are
available at each step in the workflow and the design challenges
that arise in using AM to produce parts. Different AM methods
such as Optomec’s laser-based DDM system and EOS’s powder
bed technology will be examined for quality and capability in
the process workflow. The presentation will conclude with
suggestions for determining the best options at each step to end
with the desired finished product.
11–11:55 am
Panel Presentation
Moderator: Mark Adkins, Smart Hammer Innovation
Panel Participants:
Hahna Alexander, Sole Power LLC
David Demyan, MSA
Dan Pothala, Bayer MaterialScience
Paul Pritchard, PhD, Kennametal Inc.
Matt Schrauder, MEDRAD Inc.
This panel is composed of designers and engineers from some of
Pittsburgh’s leading manufacturers. The discussion will include
benefits and challenges of bringing additive manufacturing into
the new product development area. New designs that reduce part
count, lower labor cost, speed up assembly and increase part
strength are all potential benefits of additive manufacturing. Are
they being realized in today’s leading innovation organizations?
1–1:25 pm
Additive Manufacturing and Innovative Design:
Working “Hand in Glove” to Create the Next
Generation Products
Tom Pasterik, Design Engineer, ExOne Company
Turlif Vilbrandt, CTO, Uformia
Colin Chapman, Engineer, Applied Technology Integration
Currently, the process to design new products is being
challenged to leverage the freedoms that additive manufacturing
technology offers. No longer constrained with just using
subtractive manufacturing methods or fabrication techniques,
additive technologies offer an avenue to optimize designs
(reduce weight, change inertia, tailor stiffness, enhance thermal
properties, etc.) and enable designing for function, not just
designing for geometry.
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ConferenCe Details
This presentation will focus on 3D printing using binder-jetting
technology, via volume mathematics as the design platform,
to produce innovative designs in metal that heretofore where
unattainable. This new generation 3D volume modeling
platform, which uses real, or true, volume modeling, unlike
traditional industrial approaches that are based on meshes,
parametric surfaces or voxels, will be utilized to make metal
cellular lattice structures.
the processes, as well as the most common materials will be
discussed. Samples will be handed out to the audience.
2:30–2:55 pm
Legal and Policy Issues Connected
to Consumer Use of 3D Printing
Michael Weinberg, Vice President,
Institute for Emerging Innovation, Public Knowledge
1:30–1:55 pm
Using 3D-Color Coding to Communicate Design Intent
Vito Gervasi, Director, R&D, RPR, Milwaukee School of Engineering
Over the past decade color 3D printing has become part of the
fabric of NPD in many companies. Its use for conveying more
than geometric information has also been leveraged in producing
communication models with attributes such as atomic CPK
coloring, FEA analysis results, cellular structure, topographical
mapping of planetary surfaces, and the list goes on. Recently,
as a result of facing a challenging design communication task
on a multi-colored, multi-insert, multi-shot molecule design,
the presenter determined color-coding would be the preferred
method for conveying design intent for many engineering
designs. This presentation will present our survey findings
to-date on color-coding activities and present examples of how
to use several proposed standards developed at MSOE. Case
studies will be examined in more detail and some color-coding
challenges and thought-processes will also be presented.
2–2:25 pm
How to Design for Additive Manufacturing
Technology Direct Metal Laser Sintering (DMLS)
Adam Galloway, VP Sales & Marketing,
GPI Prototype and Manufacturing Services Inc.
As AM moves beyond large commercial/industrial applications
and toward consumer markets, it is likely to receive increased
scrutiny from policymakers and other, potentially “disrupted,”
industries. The AM community will need to become familiar
with legal and policy challenges that are well known to the
internet and consumer electronics industry, such as copyright,
digital rights management, and liability for user actions. Public
Knowledge is a nonprofit consumer rights organization based in
Washington, DC that has been focusing on these issues for over
a decade. The goal of this talk is to begin to share what we are
currently doing and to sketch out a roadmap for the future.
3 – 3:25 pm
Intellectual Property Issues
in Additive Manufacturing
William J. Cass, Partner/Attorney, Cantor Colburn LLP
Intellectual property is a key component in the development
of new products and inventions in additive manufacturing.
Determining the intellectual property rights to a new design or
method at the start of a project is a critical step. Common forms
of intellectual property protection, such as contracts, patents,
trademarks and copyrights, will be reviewed. Potential pitfalls and
how to avoid them (in the context of additive manufacturing) will
also be discussed.
The presentation will start with a brief overview of the following
additive processes: DMLS, SLA, SLS, FDM, and 3D printing
including Objet and ZCorp. The presentation will then move into
the accuracy of the processes compared to one another. Finally,
it will show different examples of parts and their failures which
will also include how to design for the process. The design will
include prototype tolerances and then additive manufacturing
with a main focus on DMLS (complex geometries, internal
passageways and much more). Pros and cons for each of
50 sme.org/rapid

Direct Write Printed Materials & Electronics
10 am–3:25 pm
The technology is advancing beyond research and development.
Hear about applications of additive manufacturing for printed
electronics and other related products.
10–10:25 am
Printed Optics: Interactive Objects
and Devices using Optically Clear
Materials and Embedded Components
Eric Brockmeyer, Lab Associate, Disney Research Pittsburgh
Karl D.D. Willis, PhD, Principal Research Engineer, Autodesk
Additive manufacturing technology allows us to create unique,
personalized products for consumers and experiences for guests
of Disney parks, hotels, and resorts. We believe that the next
generation of these products will enable us to integrate interactive
display, sensing, and illumination elements. Our research using
jetted additive manufacturing explores novel techniques for
creating optical components and a variety of applications.
Our library of optical components includes: optical fiber-like
‘light pipes,’ internal light reflectors using enclosed air pockets,
micro lens arrays, and embedded opto-electronic components.
We used an Objet Connex 260 and have developed techniques
for routing light pipes, building overhanging geometry without
support, and smoothing/finishing optical components while
still in the machine. These techniques are used in a range of
applications to guide light from displays onto arbitrarily shaped
objects, to reflect light in 3D displays and lighting elements, and
to embed opto-electronic components for touch sensing. We
believe additive manufacturing of optical components will enable
unique, personalized interactive objects for consumer products
and experiences of the future.
10:30–10:55 am
Complete Electrical Assemblies Made with
Additive Manufacturing: Medical Applications
Mario Urdaneta, PhD, Staff Scientist/Engineer,
Weinberg Medical Physics
Additive manufacturing typically uses a single material type,
whether it is plastic, metal, or ceramic, to make an entire part.
Rapid prototyping parts that combine different materials (e.g.,
conductors and insulators as in an electrical motor) in a single
process are not yet an option. We have developed methods to
make rapid prototype parts that combine electrical conductors
and insulators for making MRI gradient and RF coils. The parts
include wires, insulation, cooling lines, and supporting structures.
Our primary motivation is rapid prototyping MRI wires (i.e., Litz-like
wires), which must be woven in sophisticated patterns to reduce
proximity and skin-effects that produce losses at high frequencies
and currents (patent pending). Our additive manufacturing
approach will bypass the months-long and nearly-artisanal process
of winding a Litz wire. Using additive manufacturing we can make
wires with very tight turns, leading to coils that take less space
and enable the design of MRIs with non-traditional shapes (e.g.,
dental MRI). We anticipate that eventually additive manufacturing
of conductors and insulating structures will revolutionize the
manufacturing of many electromagnetic components, especially in
high-frequency applications (e.g., hybrid cars).
11–11:25 am
Fabrication and Characterization of 3D Printed
Compliant Tactile Sensors
Jae-Won Choi, Assistant Professor, University of Akron
Morteza Vatani, PhD Candidate, University of Akron
Erik Engeberg, Assistant Professor, University of Akron
Additive manufacturing technology with a direct-write
conductive material is one promising approach to produce
compliant tactile sensors. In this work, a multi-layer compliant
tactile sensor was developed using a hybrid manufacturing
process with an existing projection micro-stereolithography
and micro-dispensing process. The sensor was designed to
detect changes in resistance as it is deformed. A compliant
skin structure was built layer-by-layer using a stretchable
photopolymer in the micro-stereolithography system to cover
the conductive elements. These sensing elements were created
within the skin material by the micro-dispensing of a compliant
conductive material during the micro-stereolithography process.
The fabricated tactile sensor consists of two layers of sensing
elements within the skin structure; there are eight stretchable
straight wires in each layer. The wires in the second layer
were orthogonally placed atop the first layer so that the sensor
can detect various external forces/motions in two dimensions.
To introduce conductivity, carbon nanotubes were dispersed
in the stretchable photopolymer. The fabricated sensor was
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ConferenCe Details
characterized by several experiments such as position, 2D
pattern, direction, and slip/roll motion detection. Finally, it is
concluded that the tactile sensor using the hybrid manufacturing
method and materials is promising for various applications such
as robotics, prosthetics, and wearable electronics.
11:30–11:55 pm
Capability Assessment of Combining 3D Printing
(FDM) and Printed Electronics (Aerosol Jet) Processes
to Create Fully Printed Functionalized Devices
Amos C. Breyfogle, DDM-Application Engineer, Stratasys
Ken Vartanian, Director of Marketing, Optomec
The need to reduce the size, weight, costs and cycle times while
also increasing functionality of highly integrated systems is a
design requirement for many consumer and military product
development programs. To date, additive manufacturing
has demonstrated new ways to produce complex physical
structures that reduce dependencies on tooling and traditional
manufacturing methods. However, industry has identified that
further benefits can be obtained through the integration of printed
electronic circuitry and components into additive manufactured
structures. This technology integration furthers additive
manufacturing, with the resulting fully functionalized devices
demonstrating the same benefits witnessed to date with additive
manufactured structures, but to a new level.
Stratasys, Optomec, and Aurora Flight Sciences collaborated
on a project to demonstrate how FDM and Aerosol Jet could be
combined to produce typical electrical components (antenna,
strain gauge, power circuit, and signal circuit) directly on
the surface of 3D-printed wing structures. The exercise was
a path finder to understand the capabilities of the combined
technologies and the integration challenges. The results were
very positive and demonstrated that the two technologies are
compatible and can support immediate applications. Additional
work is required to assess issues such as design rules, interface
requirements, performance/lifecycle expectations, and
supportability methods.
1–1:25 pm
Direct-Write and Printed Electronics in Aerospace
Joseph A. Marshall IV, Structural Designer,
Boeing Research and Technology
Airplanes, satellites, and military systems all have a need for
direct-write and printed electronics. The application space is
very large and includes replacing current systems, improving
current systems, or enabling entirely new capabilities. The needs
range from wires, sensors, antennas, lighting, and more. But the
challenging lifetime demands and requirements mean that the
industry must develop very robust products. Boeing currently
uses direct-write technology on the 747-8 and is investigating
various other applications. There are currently holes in the
development path of direct-write electronics which need to be
addressed, including connectors, part size limitations, substrate
materials, corrosion, and more.
1:30–1:55 pm
Direct Write Printing of Sensors,
Antennas & Circuitry
Jeff Brogan, PhD, CEO, MesoScribe Technologies Inc.
MesoScribe Technologies specializes in materials processing
based on its proprietary Direct Write Thermal Spray (DWTS)
technology. This additive manufacturing process deposits
materials in fine feature patterns producing sensors, antennas,
and trace patterns using robotic 7-axis automation. A wide
range of materials can be deposited including high-quality
copper conductors, ceramic dielectrics and capacitors,
sensor alloys, precious metals, and semiconductors. The
process is compatible with most substrate/component
materials including polymer laminates, fiber-filled composites,
and metallic structures. DWTS is currently used in the
construction of aerospace components providing embedded
circuitry as well as in high-temperature propulsion systems
providing diagnostic sensors (temperature, heat flux, strain)
for structural health monitoring. In addition, MesoScribe has
demonstrated the integration of UHF/VHF/L-Band antennas into
air vehicle components and other military assets for advanced
communication and signals intelligence. This presentation will
summarize the latest advances in Direct Write Thermal Spray
technology including material printing capabilities and hightemperature
sensor performance. DWTS has a significant role
52 sme.org/rapid

in the future of manufacturing, influencing product design to
reduce costs while enhancing component functionality.
2-2:25 pm
Pulsed Photonic Curing of
Printed Functional Materials
Denis Cormier, Earl W. Brinkman Professor, Industrial
and Systems Testing, Rochester Institute of Technology
Stan Farnsworth, Vice President of Marketing, NovaCentrix
The growing interest in hybrid processes that integrate
electronics within additively manufactured parts can present
significant challenges when the materials involved have
significantly different melting/curing temperatures. Photonic
curing has been used to rapidly heat printed inks and functional
films to temperatures in excess of 1000°C on low-temperature
substrates such as polymers and paper. It is therefore very well
suited for use within hybrid multi-material AM processes. This
presentation will begin with an overview of the process as well
as a discussion of its strengths and limitations. The talk will
then provide examples of high-temperature functional materials
that have been printed on polymer AM part surfaces and then
photonically cured. The talk will conclude with a discussion of
practical lessons learned.
2:30–2:55 pm
3D Structural Electronics Fabrication
Using Fused Deposition Modeling
and Direct-Write Micro-dispensing
David Espalin, Graduate Research Associate, University of Texas
at El Paso (W.M. Keck Center for 3D Innovation)
Additive manufacturing fabricated unmanned aerial vehicles
(UAVs) with integrated or printed electronics offer 3D design
and electronic packaging flexibility that may facilitate UAV
multi-role performance (i.e., reconnaissance, combat, and
logistics) and as such have received much attention in the AM
community as of late. Fundamentally, the advancement of 3D
structural electronics using AM partly hinges on effectively
interconnecting electronic components. In this particular case,
the dispensing of conductive inks on FDM produced surfaces
presented several challenges including those related to wetting,
electrical shorting between interconnections, and unintentional
ink spreading throughout the part. As a solution to some of these
issues, interconnection channels were used to confine or retain
inks at the desired locations and prevent electrical shorting or
ink spreading. Additionally, interconnection channels produced
using micromachining achieved micro-scale features. Through
this work, it was determined that FDM processing parameters
and machining depths influenced successful electrical
interconnection—which in the end, could be used to produce
functional electronic systems using FDM.
3–3:25 pm
RF Printed Circuit Structures Using
a Commercially Available Direct Print Tool
Ken Church, PhD, President, nScrypt Inc.
The mechanical segment of 3D printing has penetrated the
manufacturing barrier, but the electrical segment has not.
It is clear that mechanical structures are more mature than
their electrical counter parts, but for the electrical segment to
mature it must accomplish what the mechanical structures have
accomplished; perform at a level that meets or exceeds stateof-the-art.
3D electronic structures that have unique shape but
inferior performance will be novel but not pervasive. To address
the electrical performance issue it is imperative to involve
electrical experts in 3D printing. A number of companies and
universities are working on 3D electronic devices and this will
provide a foundation for future products, but more is needed to
make this a viable solution for true printed circuits.
nScrypt sells commercial tools for the electronic industry and
has recently added an nScrypt Fused Deposition (nFD) pump on
their micro-dispensing platform. 3D printing of next generation
printed circuit structures has the potential to penetrate an
existing printed circuit boards market; a commercially available
3D printing tool can make this viable. nScrypt and the University
of South Florida have teamed up to utilize this tool and work in
the more challenging RF regime of printed electronics. Multi-bit
RF phase shifters are challenging for any fabrication process
and 3D printing these can show improvement in ruggedness
and durability without degrading the performance. This has
implications that reach into many industries, including the
Department of Defense. In addition to the DoD, the printed
circuit boards market for consumer products is in excess of
$50B annually. For these industries to embrace the 3D printing
approach, the tools must be commercially available and
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ConferenCe Details
supported and the end products must achieve or surpass stateof-the-art.
We will demonstrate the first commercially available
tool with combined heterogeneous capability of plastics and
metals for electronic applications and specifically RF electronics.
1:30–1:55 pm
Sky’s the Limit: Advanced Rapid Prototyping
with Multi-material Capabilities
Susan York, US Consumables Business Manager, Stratasys
Innovative Applications
1–3:25 pm
Out of the box thinking leads to new ways of using additive
manufacturing. This session is a place to hear from innovators
who are testing and doing the unimaginable.
1–1:25 pm
3D Imaging and Forensic Reconstruction
of the Human Face
Shayne A. Kondor, Medical Modeling Engineer,
Naval Postgraduate Dental School
Joe Mullins, Forensic Artist,
National Center for Missing and Exploited Children
There are over 100,000 missing persons in the United
States and approximately 45,000 unidentified sets of human
remains. A significant proportion of the unknown remains are
skeletonized, making identification difficult. DNA and dental
records are extremely useful identifiers, but the dissemination
of facial reconstructions, and the subsequent recognition
of the unidentified person by an investigative agency, family
member or friend is still one of the most common ways that
these individuals are identified. To put a face on these victims,
forensic artists are able to reconstruct a probable face on a
skull using a combination of anatomical science and artistic
skill. The reconstruction process is classically performed by
clay sculpted over the skull. This process is labor intensive and
expensive. To expedite this process forensic artists now benefit
from 3D scanning technologies, allowing accurate models of
the skull to be obtained for digital reconstruction of the face.
Digital reconstruction of the face is performed in a software
application. Tangible 3D models of the reconstruction are
printed using additive manufacturing technologies. Case studies
will demonstrate different imaging options to obtain a skull
model for the reconstruction process, the digital reconstruction
process, and the additive manufacturing options used to obtain
physical models.
One of the major challenges in the prototyping stage of product
development is to produce a fully-representative model of the
intended end-product. In many industries, this is complicated
by the fact that the final product is not of a single, homogenous
material, but is rather an assembly of different materials and
properties. Objet inkjet-based technology is the only 3D printing
technology of its kind in the world able to selectively place
different materials in a single 3D printed prototype and compose
two materials to create varying composites, Digital Materials, to
closely match very specific material properties. With over 100
different materials and Digital Material combinations to choose
from, including rigid to rubber-like, opaque to transparent and
standard to engineering plastic performance, the sky is now
the limit to creating accurate prototypes that match closer than
ever before the aesthetic look, tangible feel and true function of
complex end-products.
2–2:25 pm
Making Stuff in the Connected Age
Mickey McManus, President & CEO, MAYA Design
In 2013, there are more transistors in the world than grains of
rice. Each year we make billions of computing devices and put
them into nearly every significant thing we manufacture. We
have literally permeated our world with computation. Computers
already vastly outnumber people, but in a few short years, their
number will climb into the trillions. We are quickly learning how
to make those processors communicate with each other, and
with us. Instead of information being “in” computers; people,
products, environments, and cultures will begin to live “in” the
information. In this burgeoning ecology, strange new varieties
of connected products, services, environments, and people
will proliferate. Atoms and bits will connect in ways nobody
can predict. 3D printing of electronic devices is already a
reality. What will manufacturing look like when every sheet of
printed paper has the computing power of the newest iPad®?
When connectivity spreads to ordinary objects and they are
newly vulnerable to viruses or bad updates, complexity will
be inevitable. But untamed, malignant complexity is not. This
54 sme.org/rapid

presentation will cover the intersection of design, technology,
and manufacturing in the Age of Trillions.
2:30–2:55 pm
Advantages of Selective Contour Photocuring (SCP)
Technology for Additive Manufacturing
Martin Forth, Vice President, EnvisionTEC GmbH
Selective contour photocuring (SCP) is a promising new
technology which enables high-speed curing without sacrificing
accuracy, yielding higher productivity as well as better control
over material shrinkage during the build process. In a build area
of 279 x 198 x 203mm, SCP technology enables a build speed
up to 10mm per hour for the full build envelope at 50 microns, Z
resolution inversely proportional to the X dimension, and 20 mm
per hour for half of the X/Y build envelope.
Curing speed is 1.5 inches per second in the X dimension,
while up to 2000 partial images are cured per second in the Y
dimension during X motion, enabling X/Y feature resolution down
to 19 microns. Resolution in the Z dimension is 25–100 microns,
depending on material, and may be adjusted by the user. In
addition, viscosity of the material is no longer a constraint with
SCP: liquid photopolymer may be filled with zirconia, aluminum
oxide, carbon fiber, or other suspended materials. Notably, such
materials may not be jetted; jet technologies require the use of
materials below 60 centipoise (cP) dynamic viscosity. Viscosities up
to 3000 may be accommodated (e.g., EC500 wax-based material).
3–3:25 pm
Design Innovation Enabled by Additive
Manufacturing
Prabhjot Singh, PhD, Manager, GE Global Research
Additive manufactring is enabling new degrees of design freedom
previously not possible in new product developments. GE
reseachers have been working on additive technologies for two
decades. The company's level of activity and investments in additive
have substantially increased during the past five years, as it
has recognized the vast potential of this technology to transform
its own products.
This presentation will provide examples across GE's industrial
portfolio in aviation, health care, oil & gas and more of how GE
researchers are exploiting this capability across its product
portfolio to achieve higher levels of efficiency and performance in
its products and manufacturing operations. There will be discussion
on GE's efforts to foster an ecosystem that accelerates the
growth and scale up of additive manuacturing to meet the largerscale
industrial needs of companies like GE to maximize the
impact this technology can have in transforming manufacturing.
In competing technologies, use of the X and Y galvanometer
mirrors creates distortion in two dimensions during the curing
process. This distortion of the beam as it is reflected off
galvanometer mirrors must be corrected in both the X and Y
dimensions. With SCP, optical correction is only required in the
Y dimension, yielding a more streamlined build process as well
as simpler long-term machine maintenance. The non-projection
light source is reliable, requires no calibration over long periods
of time, and allows for better control of the curing path. Higher
uptime, lower maintenance costs, greater affordability, and
enhanced Quality/Reliability/Durability (QRD) are the result.
Image courtesy Jim Stanis
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FLOOR PLAN
R A P I D 2 0 1 3
June 11-12, 2013
David L. Lawrence Convention Center
Pittsburgh, PA
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56 sme.org/rapid

EXHIBITORS
The following is an alphabetical
list of exhibitors and companies
with technologies on display.
A
ACTeCh NorTh AmeriCA....................................827
4343 Concourse Dr Ste 350
Ann Arbor Michigan 48108-8802
734-913-0091 • 734-913-0095
www.rapidcastings.com
ACTech designs and produces casting prototypes
and small batches for various industries:
automotive, aerospace, machine and plant
manufacturers. We have design, production, machining
and test capabilities all under one roof.
State-of-the-art rapid prototyping processes,
combined with CNC pattern making and CNC
machining, provide for extremely fast production
of prototypes.
AeroTeCh iNC ........................................................927
101 Zeta Dr
Pittsburgh Pennsylvania 15238-2897
412-963-7470 • 412-963-7459
www.aerotech.com
Aerotech manufactures high-precision motion
control products required for additive manufacturing
applications in the laboratory and in
production environments. Our products include
automated nanopositioners; planar and rotary
air-bearing stages; high-speed linear motor
gantries; mechanical-bearing linear, rotary and
lift stages; brushless linear and rotary servomotors
and drives; stand-alone and software-based
motion controllers; goniometers; gimbals/optical
mounts; and custom motion subsystems.
AFiNiA.......................................................................310
8150 Mallory Ct
Chanhassen Minnesota 55317-8586
888-215-3966 • 952-556-1620
www.afinia.com
Afinia will be showing its award winning 3D
printer, and a full line of ABS filament. Our H
series 3D printer was voted “Best Overall Experience”
in the recent Make Magazine 3D Printer
shootout. Live 3D printing demonstrations will be
held continuously during the day.
AmeriCAN FouNdry SoCieTy...........................826
1695 N Penny Ln
Schaumburg Illinois 60173-4555
847-824-0181 • 847-824-7848
www.metalcastingdesign.com
The leading U.S. based metalcasting society
that assists member companies (metalcasting
facilities, diecasters and industry suppliers) and
individuals to effectively manage all production
operations, profitably market their products
and services and to equitably manage their
employees. The American Foundry Society also
promotes the interests of the metalcasting industry
before the legislative and executive branches
of the federal government. With the direction of
its volunteer committee structure, the professional
staff of the American Foundry Society
provides support in the areas of technology,
management and education to further activities
that will enhance the economic progress of the
metalcasting industry.
AmeriCAN PreCiSioN ProToTyPiNg LLC ......521
19503 E 6th St
Tulsa Oklahoma 74108-7959
918-266-1004 • 918-266-1019
www.approto.com
American Precision Prototyping, LLC (APP), a
privately held services company, is the premier
rapid prototyping and custom part manufactured
parts provider in the United States. APP is ITAR
registered and ISO compliant. APP offers instant
online quoting 24x7, complete project solutions
from design to prototyping to production utilizing
the latest equipment and materials in-house,
providing unsurpassed customer service, and offering
their customers a 100% quality guarantee.
WWW.APPROTO.COM
AmT PheNix SySTemS ........................................610
1201 Oakton St Ste 1
Elk Grove Village Illinois 60517
847-258-4475
www.amtincorp.com
AMT, Inc., a North American subsidiary of Phenix
Systems, headquartered in France. Found in 2000
from the conviction that in the future rapid laser
sintering equipment would become the standard,
it has opened the way to new possibilities by
designing & fabricating additive manufacturing
systems that use laser sintering of metal
and ceramic powders. Our customers enjoy
the flexibility of using their own metal powders
while attaining industry best finishes (5Ra) and
mechanical properties.
Amug........................................................................425
9310 Tpnga Canyon Blvd Ste 210
Chatsworth California 91311-5713
262-385-7471
www.additivemanufacturingusersgroup.com
The Additive Manufacturing Users Group
(AMUG) is an organization that educates and
advances the uses and applications of additive
manufacturing (AM) technologies. AMUG
members use any commercial AM/3D printing
technologies from companies such as Stratasys,
SLM Solutions, Mcor Technologies, Renishaw
and 3D Systems.
ArCAm AB ............................................ 821
Krokslätts Fabriker 27A
mölndal Se-431 37
Sweden
+46-31-710-32-00 • +46-31-710-32-01
www.arcam.com
See ad in this issue
Arcam provides a cost-efficient Additive
manufacturing solution for production of
metal components. Arcam's eBm ® technology
offers freedom in design combined
with excellent material properties and high
productivity. Arcam is an innovative partner
for manufacturing in the orthopedic implant
and aerospace industries, where we deliver
customer value through our competence and
solution orientation.
AriSTo CAST iNC ...................................................811
7400 Research Drive
Almont Michigan 48003-8515
810-798-2900 • 810-798-2730
www.aristo-cast.com
Being the leader in the investment casting industry
we can produce castings from math data, in
as short as 2 working days, without tooling using
one of our many additive manufacturing methods.
Our castings are produced with the highest
degree of dimensional and metallurgical integrity.
We cast all air-melt alloys including Magnesium
in both proto-type and production volumes for
virtually any industry. Let our TEAM make your
idea a reality. Contact us at 810.798.2900 or www.
aristo-cast.com
ArmSTroNg moLd CorP ...................................308
6910 Manlius Center Rd
East Syracuse New York 13057-8507
315-437-1517 • 315-437-9198
www.armstrongmold.com
Armstrong Mold is an industry leader providing
prototype / short run production of cast metal
and molded plastic parts in quick time frame.
Armstrong is ISO 9001 and ITAR registered.
Armstrong is able to provide high quality machined
aluminum and zinc castings via multiple
processes including: RPM , Air Set Sand, Graphie
Die Casting and our One Shot Casting. Armstrong
also has a RIM ( Reaction Injection Molding )
facility providing high quality molded foamed and
rigid polyurethanes.
B
BALLy deSigN iNC .................................................724
810 Penn Avenue
Pittsburgh Pennsylvania 15222
412-621-9009 • 412-621-9030
BJB eNTerPriSeS iNC .........................................720
14791 Franklin Ave
Tustin California 92780-7215
714-734-8450 • 714-734-8929
www.bjbenterprises.com
BJB Enterprises, Inc. formulates and
manufactures liquid polyurethane, epoxy,
and silicone systems. BJB also designs and
manufactures high-quality equipment for
material processing including meter-mix
dispensing equipment, vacuum pump systems
and rotational casting machines.
BouNdAry SySTemS .......................................... 304
7055 Engle Rd Ste 601
Middleburg Hts Ohio 44130-8461
440-274-0291 • 440-274-0295
www.boundarysys.com
Boundary Systems is a reseller of advanced
CAD/CAM/CAE, Product Lifecycle Management
software, and 3D Printers. By using the best
technology from PTC and Stratasys Boundary
Systems helps companies with new product
development and manufacturing by helping them
streamline processes and implement the most
modern tools available.
6/2013 – RAPID 57

EXHIBITORS
C
C&A Tool EnginEEring inC .............................823
4100 N US HWY 33
Churubusco Indiana 46723
914-572-2939 • 260-693-9571
www.catool.com
C&A Tool Engineering is a contract manufacturing
company. One of our many manufacturing
capabilities is DMLS (direct metal laser sintering).
At this present time we have four DMLS machines
producing parts on a daily basis. As well
as DMLS we also offer the following manufacturing
capabilities, EDM, Extrude Hone, Grinding,
Gun Drilling, Five Axis Milling and Turning.
CApTurE 3D inC.....................................................709
Headquarters 3505 Cadillac Ave Ste F1
Costa Mesa California 92626-1431
714-546-7278 • 714-546-7279
www.capture3d.com
Capture 3D is a leader in innovative turnkey
3D metrology solutions that optimize scanning,
inspection, and reverse engineering applications
for product development, manufacturing, and
production. Our advanced technology and intelligent
software quickly obtains accurate full part
geometry to rapidly solve engineering issues,
prevent future problems, eliminate costs/waste,
and improve quality.
Cgi 3D SCAnning..................................................407
15161 Technology Dr
Eden Prairie Minnesota 55344-2273
952-937-2005 • 952-937-3018
www.CGI3DScanning.com
CGI offers automated Cross Sectional 3D
Scanning equipment and services for complete
internal/external complex inspection and
reverse engineering. CGI’s Spec.Check software
measures hidden critical features of small plastic
injection molded parts with plus/minus 0.0008"
accuracy. Its templating feature reduces failure
analysis/inspection time for multiple-cavity parts.
CiDEAS inC ........................................... 620
125 Erick St unit A115
Crystal lake illinois 60014-4500
847-639-1000 • 847-639-1983
www.buildparts.com
See ad in this issue
Since 1998 Cideas been a leader in rapid prototyping
3D printing and Additive Manufacturing.
utilizing over 20 in-house machines,
Cideas offers all major 3D printing services
under one roof, including; SlA, SlS, FDM,
polyjet, as well as a variety of part finishing
options and urethane castings. For 2013; Cideas
has expanded its SlS and SlA offerings
with four new large frame 3D AM machines
and became the first Service Bureau to run
Xtreme White 200 in an ipro 8000.
CiTiM gMBh............................................................406
Steinfeldstrasse 5
Barleben 39179
Germany
49 39203 51060 • 49 39203 510699
www.citim.de
Citim GmbH is a leading German service provider
for Additive Layer Manufacturing. Within a very
short time premium components from metal
are produced by citim on our machines: two
machines from EOS (M270 and M280) and three
machines from SLM Solutions GmbH (250 HL,
280 HL with 400 watts fibre laser and 280 HL
with a new 1 KW fibre laser). Beyond that citim
may look back to many years of experiences
in the field of rapid tooling. Innovative casting
processes complete our range of services.
ConCEpT lASEr gMBh ........................................710
An der Zeil 8
Lichtenfels Bavaria 96215
Germany
499571949238 • 499571949249
www.concept-laser.de
Concept Laser GmbH is an independent company
that forms part of Hofmann Innovation Group
GmbH from Lichtenfels (Germany). Since the
company was founded in 2000, it has worked
across different sectors as a driving innovator in
the field of metal additive manufacturing technology
using the patented LaserCUSING ® process.
This technology allows the fabrication of both
mold inserts with conformal cooling and direct
components for the jewelry, medical, dental,
automotive and aerospace sectors.
D
DElCAM....................................................................306
275 E South Temple Ste 305
Salt Lake City Utah 84111
801-575-6021 • 801-575-5017
www.delcam.com
Delcam is one of the world’s leading suppliers of
advanced CADCAM solutions for manufacturing
industry. Delcam’s range of design, manufacturing
and inspection software provides complete,
automated CADCAM solutions, to take complexshaped
products from concept to reality. The
software allows users to boost productivity,
improve quality and reduce lead times. Delcam’s
has solutions for every industry ranging from
mold making, plastics, rapid prototyping to
reverse engineering.
DElTA MiCro FACTory Corp .............................820
Rm 1008, Tower A, Third Property Building, No.1
Shuguang Xili, Chaoyang District,
Beijing 100028
China
8610-58221295 • 8610-58221296
www.pp3dp.com
PP3DP is specialized in the marketing and sales
of personal portable 3D printers and accessories.
Our UP line of 3D printers is high-quality, userfriendly
and affordable. PP3DP is dedicated to
providing workflow solutions that will revolutionize
the way that designers, engineers, architects
and others create physical models. We pride ourselves
on manufacturing products that increase
productivity, reduce time to market, and lower
the cost involved during the design process.
DESkTop EnginEEring .......................................727
1283 Main St PO Box 1039
Dublin New Hampshire 03444-1039
603-563-1631 • 603-563-8192
www.deskeng.com
DE is the market leader in technology information
for Design Engineers. Our print magazine, website
and newsletters focus on what design teams
need to know about CAD, PLM, Visualization,
Analysis, Simulation, 3D Scanning, 3D Printing,
Rapid Prototyping and the computer systems that
enable great design.
DirECT DiMEnSionS inC ....................................326
10310 S Dolfield Rd
Owings Mills Maryland 21117-3558
410-998-0880 • 410-998-0887
www.directdimensions.com
For over 18 years, Direct Dimensions has provided
the most comprehensive 3D imaging, scanning,
digitizing, and digital modeling services,
products, training, and support for the solution
of 3D-related applications in industries including
engineering, manufacturing, entertainment, art
and architecture. We specialize in the on-site
application of 3D scanning systems and conversion
of 3D point cloud data into high-accuracy
high-quality CAD models.
DirECTED MAnuFACTuring ..............................409
1007 S Heatherwilde Blvd Ste 700
Pflugerville Texas 78660-5253
512-990-9100 • 512-857-9911
www.directedmfg.com
Directed Manufacturing Inc specializes in
additive manufacturing for production. AM
systems from 3D Systems, Renishaw and EOS
for plastic and metals are used in conjunction
with our machining and molding systems. All
product is delivered to customer process and
material specification requirements. Product has
traceability to raw material source and product
realization is done within ISO9001:2008 and
AS9100C standards. Direct Metal Laser Sintering
and Plastic Laser Sintering.
DM3D TEChnology llC ......................................906
2350 Pontiac Rd
Auburn Hills Michigan 48326-2461
248-409-7900 • 248-409-7901
www.dm3dtech.com
DM3D Technology is a leader in laser additive
manufacturing with over 29 patents. Our Direct
Metal Deposition (DMD) technology along with
proprietary software and recipes involving material/process
knowledge is used in commercial
applications involving hardfacing, remanufacturing
and free form fabrications. We do product
development, run production parts and build
customized production ready equipments for our
customers in automotive, oil & gas, aerospace,
heavy equipments and other industries.
DSM SoMoS ...........................................................421
1122 Saint Charles St
Elgin Illinois 60120-8443
847-697-0400 • 847-468-7785
www.dsm.com/somos
In the area of Additive Manufacturing, DSM
Functional Materials is a leading innovator
of high-performance Somos ® materials for
stereolithography—a distinct and unique subset
of the additive manufacturing process. Somos ® is
a brand of Royal DSM N.V.—a global science-
58 sme.org/rapid

ased company active in health, nutrition and
materials. More information about these products
can be found at: www.dsm.com/somos.
E
EFESTO LLC ..............................................................920
3400 Woodhill Circle
Superior Township Michigan 48198
734-657-4345 •
www.efesto.us
EFESTO will develop and deliver market driven
solutions including a comprehensive range of
standalone, turnkey and automated 3D metal
printing systems for desktop, laboratory, factory
and large scale field deployment. It will also
launch innovative business models, including
long term services partnering arrangements
with select customers, allowing the user and
EFESTO to jointly profit from the use of EFESTO’s
solutions.
EnviSiOnTEC inC ..................................................402
15162 S. Commerce Dr
Dearborn Michigan 48120
313-436-4300 • 313-436-4303
www.envisiontec.com
EnvisionTEC is a world leader in rapid prototyping
and rapid manufacturing equipment. With
thousands of EnvisionTEC systems in the field
since 2002, the simplicity and reliability of our
DLP-based technology has made the systems
very popular in a broad range of markets. The
resolution of fine detail is unmatched by any other
rapid prototyping system, regardless of price.
EnvisionTEC carries a wide range of materials for
prototyping, casting, molding and more.
EOS GmbH - ELECTrO OpTiCaL SySTEmS .......412
28970 Cabot Dr Ste 700
Novi Michigan 48377-2978
248-306-0143
www.eos.info
EOS is the technology and market leader for
design-driven, integrated e-Manufacturing
solutions for additive manufacturing (AM, or
“Industrial 3D Printing”). EOS offers a modular
solution portfolio including systems, software,
materials and material development as well as
services. As an industrial manufacturing process
it allows the fast and flexible production of highend
parts based on 3D CAD data at a repeatable
industry level of quality.
EQuaLiTy TECH inC...............................................322
13416 West Star Drive
Shelby Twp Michigan 48315
248-247-3800 • 248-247-3840
www.eqtinc.com
eQuality Tech Inc., based out of Shelby Twp,
MI is highly experienced in the advanced
technologies of 3D Scanning and 3D Printing.
When it comes to engineering and manufacturing,
we have the capacity to support all your 3D
technology and data processing needs. We can
integrate our technologies all while providing a
viable ROI. eQuality Tech, Inc., supports engineers,
designers and manufacturers to shorten
the design and manufacturing cycles.
EraSTEEL .................................................................726
Tour Maine-Montparnasse, 33, avenue du Maine
Paris Cedex 15 75755
France
33 1 45 38 63 26
www.erasteel.com
Erasteel offers Pearl ® Micro fine metal powders
produced by VIM gas atomization (under
vacuum). Available in tailor made compositions
and small batches, Pearl ® Micro powders are
recommended for various additive manufacturing
processes (SLM, EBM, 3D printing, laser
cladding etc.). Alloy range include standard and
customized Nickel base powders as well as Cobalt
base, stainless and tool steels or maraging
steels. Contact: powder@eramet-erasteel.com
Ex OnE COmpany .................................................704
127 Industry Blvd
Irwin Pennsylvania 15642-3461
724-863-9663 • 724-864-9663
www.exone.com
The Ex One Company supplies services, systems
and solutions for additive manufacturing using
three-dimensional printing (3DP) in metal, glass
and sand. The 3DP process builds an object-or
mold for an object-layer by layer out of powdered
material, a chemical binder and a digital file.
Industrial-strength materials are used to create
prototypes and short-run production parts. 3DP
provides design flexibility and significant time
savings over traditional manufacturing methods.
ExaCT mETrOLOGy inC/arTEC .........................925
4766 Interstate Dr
Cincinnati, OH 43017
614-264-8587 • 614-760-9162
www.exactmetrology.com
F
FabriSOniC LLC .....................................................807
1250 Arthur E Adams Dr
Columbus Ohio 43221-3560
614-688-5223 • 614-688-5001
www.fabrisonic.com
Fabrisonic provides equipment and service
related to the patented Ultrasonic Additive
Manufacturing (UAM) process which uses the
power of sound to merge layers of metal foil.
The process produces true metallurgical bonds
in a variety of metals such as aluminum, copper,
stainless steel, and titanium. The solid state
nature of the UAM bond allows for welding of
dissimilar metals enabling production of custom
metal matrix composites and the ability to embed
objects or sensors in a metal substrate.
FarO TECHnOLOGiES inC ....................................309
250 Technology Park
Lake Mary Florida 32746-7115
407-333-9911 • 407-333-4181
www.faro.com
FARO is a global technology company that
develops portable devices for 3D measurement,
inspection, imaging and documentation.
Our focus is simplifying our customers’ work
with tools that make them more productive. Our
commitment to our customers extends beyond
product performance…with FARO you have 3D
Measurement peace of mind.
FaTHOm ....................................................................424
315 Jefferson St
Oakland California 94607-3537
510-281-9000 • 510-281-9001
www.studiofathom.com
FATHOM is your all in one product development
partner offering 3D printing, rapid prototyping
and manufacturing services. From concept
consulting and design, to rapid prototyping and
production, FATHOM will be your partner through
the entire process.
FinELinE prOTOTypinG.......................................721
9310 Focal Point Suite 100
Raleigh North Carolina 27617
919-781-7702 • 919-781-7612
www.finelineprototyping.com
FineLine Prototyping Inc. is a rapid prototyping
service provider to the medical device industry.
Specializing in high-accuracy, high-resolution
parts, the company operates 18 Viper HR
stereolithography machines and is among the
first in the industry to offer high-resolution metal
prototypes. FineLine also offers selective laser
sintering and custom finishing. Ask about microresolution
parts.
G
GE...............................................................................512
3135 Easton Turnpike
Fairfield, Connecticut 06828
513-733-1611 • 513-733-8775
www.ge.com
GE works on things that matter. The best people and
the best technologies taking on the toughest challenges.
As one of the world's largest users of additive
manufacturing technologies, GE works to create
revolutionary advances across multiple industries
such as aviation, energy and healthcare. The appliciation
of additive techniques is one way GE is
redefining and leading advanced manufacturing.
GOmEaSurE3D......................................................307
524 Sunset Dr
Amherst Virginia 24521-2527
434-946-9125 • 480-393-5876
www.gomeasure3d.com
GoMeasure3D offers the best available scanning
and portable cmm equipment from around
the world. From the MicroScribe digitizer with
optional Kreon laser scanner attachment to the
Baces cmm with optional Solano laser scanner
attachment to the 3D3 line of scanners that
enable scanning quality only found in much more
expensive systems, our superior line of hardware
and software products is only matched by our
friendly customer service.
Gpi prOTOTypE & manuFaCTurinG
SErviCES inC........................................................707
940 North Shore Drive
Lake Bluff Illinois 60044-2202
847-615-8900 • 847-615-8920
www.gpiprototype.com
GPI Prototype sets the standard for rapid
prototyping and additive manufacturing services
for all industries. These technologies are ideal
for low-volume production of metal, plastic and
urethane components, resulting in significant
time and cost savings. DMLS is GPI’s primary
technology great for the creation of conformal
cooling channels within tools and tooling inserts,
as well as customized medical implants.
6/2013 – RAPID 59

EXHIBITORS
H
Harvest tecHnologies ....................................312
815 Kirkley Blvd
Belton Texas 76513-4158
254-933-1000 • 254-298-0125
www.harvest-tech.com
Harvest Technologies is an advanced provider
of additive manufacturing services. We produce
top-quality plastic, composite, and metal production
parts/assemblies, functional prototypes,
presentation models, patterns, and end-use
parts/assemblies via laser sintering (LS/SLS,
DMLS), stereolithography (SL/SLA), 3-D printing,
urethane casting, and CNC machining. Harvest is
certified under the AS9100 and ISO 9001 quality
management systems and services a wide array
of industries and applications.
incodema inc .......................................................311
407 Cliff St
Ithaca New York 14850-2009
607-277-7070 • 607-277-5511
www.incodema.com
I
Incodema is a full service rapid prototype
provider, offering a full range of technologies
& processes. Our capabilities include sheet
metal stampings, metal forming, laser cutting,
Microcut, photochemical machining, wire EDM,
DMLS & CNC machining to 3D printing using
SLA, Polyjet, FDM & urethane castings. We can
manufacture your parts quickly & guarantee full
turnkey assemblies all in house
innovative Polymers inc ...............................812
208 Kuntz St
Saint Johns Michigan 48879-1172
989-224-9500 • 989-224-1400
www.innovative-polymers.com
Innovative Polymers Inc will display and demonstrate
high-performance polyurethane systems
designed to simulate thermoplastics in a prototyping
or low-volume production applications.
intecH industries inc ......................................924
7180 Sunwood Dr NW
Ramsey Minnesota 55303-5100
763-576-8100 • 763-576-8101
www.intechrp.com
ech’s RP&AM Center houses three 3D Systems
iPro TM 9000 SLA ® production printers, five 3D
Systems iPro TM 8000 SLA ® production printers, six
3D Systems Viper TM Si2 SLA ® systems, one Objet
Connex500 TM 3D printer, two Objet Connex350 TM
3D printers, one Objet Eden500 TM 3D printer, one
Objet Eden333 TM 3D printer and one Stratasys
Titan TM 3D production system.
invest cast inc ...................................................410
716 39th Ave NE
Columbia Heights Minnesota 55421-3810
763-788-6965 • 763-788-7029
www.investcastinc.com
We specialize in high quality high tolerance
production and prototype metal castings. Our experience
and innovation in the industry has made
us the nation`s largest manufacturer of metal
cast prototypes servicing the diecast, investment
cast, sand cast, forging and stamping industries.
From file to part in days not weeks, Invest Cast
Inc. will add great value to your next project.
L
laser reProductions ......................................426
950 Taylor Station Rd Ste E
Gahanna Ohio 43230-6670
614-552-6905 • 614-552-6907
www.laserrepro.com
Laser Reproductions is a total-solutions product
development company specializing in engineering
and rapid prototyping. Services include SLA,
SLS, FDM, CNC, DMLS, and RTV Tooling. Utilizing
its capacity of 19 SLA machines, a variety of
materials, and full finish and model shop capabilities,
the company helps its diverse client base
get quality parts in a timely manner.
layerwise nv .......................................................526
Kapeldreef 60
Leuven 3001
Belgium
32 16 298 420 • 32 16 298 319
www.layerwise.com
LayerWise is a leading European production
center exclusively focusing on Metal 3D
Printing Prototyping and Serial Production. 3D
printed monolithic metal parts exhibit better
performance, functionality and reliability than
their predecessor assemblies, using less
material and no scrap. LayerWise executes
projects in machine construction, precision
mechanics, food en pharmaceutics, chemistry
en petrochemistry, oil and gas, automotive and
medical industry segments.
M
m. Braun, inc .......................................................921
14 Marin Way
Stratham New Hampshire 03885
603-773-9333 • 603-773-0008
www.mbraun.com
MBRAUN has over thirty year’s experience
providing inert glove box solutions for clean
environments. Our core market segments include
university, OLED research and mass production,
lithium ion battery research and production, high
intensity discharge lamps and ceramic lamp
production, inert gas welding, pharmaceutical,
nuclear containment and research in chemistry
applications.
materialise usa ......................................403 & 502
44650 Helm Ct
Plymouth Michigan 48170-6061
734-259-6445 • 734-259-6441
www.materialise.com
Materialise is a world leader in software solutions
for processing and editing files for Additive
Manufacturing. Our solutions maximize your
equipment investment by improving the efficiency
of the entire AM process from CAD translation,
data preparation in Magics, automation of
tedious tasks, advanced support generation, part
traceability and more. Our Mimics ® Innovation
Suite is a complete CT-based, 3D medical imaging
software solution for biomedical engineers,
researchers, and clinicians.
mcor tecHnologies ..........................................802
Unit 1, IDA Business Park Ardee Road
Dunleer Co Louth
Ireland
781-718-0250 • 781-862-0566
www.mcortechnologies.com
Mcor Technologies Ltd is an innovative manufacturer
of the world’s most affordable, full-color
and eco-friendly 3D printers. They are the only
3D printers to use ordinary business-letter paper
as the build material, a choice that renders
durable, stable and tactile models. Established in
2004, Mcor’s vision is to make 3D printing more
accessible to everyone. The company operates
internationally from offices in Ireland, the UK and
US. www.mcortechnologies.com.
medical design magazine .............................825
1300 E 9th St
Cleveland Ohio 44114-1501
216-931-9426 • 913-513-3775
www.medicaldesign.com
Medical Design explores and reports on the
cutting edge manufacturing and design technologies
device OEM`s need to continue to innovate
and excel in their work.
medical modeling inc .....................................909
17301 W Colfax Ave Ste 300
Golden Colorado 80401-4892
303-273-5344 • 303-273-6463
www.medicalmodeling.com
Medical Modeling is an additive manufacturing
(AM) service bureau specializing in servicing
the medical device industry. We have in-house
capabilities for 1) AM production of tools, instruments
and templates using SLA, 3DP & Polyjet
technologies with several options for ISO 10993
materials, 2) AM for off-the-shelf or customized
implant production using EBM in Titanium alloy,
and 3) personalized surgery technology. We are
a single-stop source for AM projects in the medical
device field.
met-l-Flo inc ........................................................527
720 N Heartland Dr Ste S
Sugar Grove Illinois 60554-9864
630-409-9860 • 630-409-9869
www.met-l-flo.com
MET-L-FLO, INC is here for your Direct Manufacturing
and Rapid Prototyping needs. We stand
for INTEGRITY in business, INNOVATION through
technology, and COMMITMENT to excellence
Met-L-Flo, Inc. is a provider of Additive Manufacturing
services offering several complimentary
services as well. We have experienced service
representatives ready to serve you. Please stop
by and see us at booth 527 during your visit to the
Rapid Exposition.
microtek FinisHing ...........................................420
5229 Muhlhauser Rd
Hamilton Ohio 45011
513-766-5600 • 513-766-4999
www.microtekfinishing.com
MicroTek Finishing’s Micro-Machining Process
(MMP) is the only surface finishing technology of
its kind in the world. MMP produces a perfectly
controlled surface that is both repeatable and
traceable. MMP is unique in its ability to selectively
remove specific components of roughness
evenly across the entire surface of the part.
60 sme.org/rapid

Motorola SolutionS .......................................621
8000 W Sunrise Blvd Rm 4J9
Plantation Florida 33322-4170
954-723-3856 • 954-723-4934
www.oneprototype.com
Motorola Solutions’ Rapid Prototyping Services
offers quick turn rapid prototyping in 3D printing,
CNC Machining, Appearance Model Making, and
prototype and low volume production Tooling and
Molding. We also offer 3D Optical Scanning for
CAV Analysis and Reverse Engineering
N
national additive Manufacturing
innovation inStitute .................................... 902
486 Cornell Road
Blairsville Pennsylvania 15717
724-539-8811 • 724-459-8500
www.namii.org
In August 2012, the National Additive Manufacturing
Innovation Institute (NAMII) was established
in Youngstown, Ohio, as the pilot institute
under the National Network for Manufacturing
Innovation (NNMI) infrastructure. Driven by the
National Center for Defense Manufacturing &
Machining (NCDMM), NAMII serves as a nationally
recognized additive manufacturing center of
innovation excellence, working to transform the
U.S. manufacturing sector and yield significant
advancements throughout industry.
nikon Metrology inc .......................................824
12701 Grand River Rd
Brighton Michigan 48116-8506
810-220-4360 • 810-220-4300
www.nikonmetrology.com
Nikon Metrology, Inc. offers the most complete
and innovative metrology product portfolio,
including state-of-the-art vision measuring
instruments complemented with optical and
mechanical 3D metrology solutions. These reliable
and innovative metrology solutions respond
to the advanced inspection requirements of
manufacturers active in aerospace, electronics,
automotive, medical, consumer and other
industries. Systems are available in both fixed
and portable configurations.
north Star iMaging inc .................................321
19875 S Diamond Lake Rd
Rogers Minnesota 55374
763-463-5650 • 763-463-5651
www.4nsi.com
North Star Imaging, Inc. offers a complete line
of state-of-the-art Digital X-ray and Computed
Tomography (CT) systems. Established in 1986,
NSI’s corporate facility is headquartered in MN
where systems are designed and built by highly
trained innovative engineers. NSI is the domestic
leading manufacturer of Turn-Key 2D Digital X-
ray as well as 3D X-ray CT for the Industrial Nondestructive
Testing industry. NSI was acquired
by Illinois Tool Works (ITW), an international
business leader, in 2010.
nScrypt inc. .........................................................908
12151 Research Pkwy Ste 150
Orlando Florida 32826-2920
407-275-4720 •
www.nscrypt.com
nScrypt sells micro-dispensing platforms. Our
patented nScrypt SmartPumpô dispenses the
widest range of materials of any micro-dispensing
pump on the market to include low viscous
materials such as inks to high viscosity pastes,
epoxies & solders. It can control volumes of less
than 100 picoliters and including precision starts
and stops. Our platform ranges from 150mm in XY
to more than 1 meter & includes many feedback
options including vision and Z sensing for conformal
or non-flat surfaces.
O
optoMec inc .........................................................903
3911 Singer Blvd NE
Albuquerque New Mexico 87109-5841
505-761-8250 • 505-761-6638
www.optomec.com
Optomec is a profitable, rapidly growing company
whose breakthrough Aerosol Jet and LENS
Additive Manufacturing solutions are spearheading
the next generation in Electronics, Energy,
Life Science and Aerospace/Defense manufacturing.
Optomec is a recognized leader in the
field of Additive Manufacturing, or 3D Printing, a
revolutionary approach that has proven advantages
in reducing cost, improving functionality,
and shortening time to market.
P
penn State center for innovative
MaterialS proceSSing through
direct digital depoSition ............................907
ARL Penn State P O Box 30
State College Pennsylvania 16804
814-865-3940 • 814-865-0865
www.cimp-3d.org
The Center for Innovative Materials Processing
through Direct Digital Deposition (CIMP-3D)
at Penn State has a broad mission to advance
enabling technologies required to successfully
implement additive manufacturing technology
for critical components and structures, provide
technical assistance to industry through selection,
demonstration, and validation of additive
manufacturing technology, and promote the
potential of additive manufacturing through training
and education.
pennSylvania departMent of
coMMunity & econoMic developMent ..1001
400 N St, 4th Floor Commonwealth Keystone Bldg
Harrisburg Pennsylvania 17120
717-720-1332 • 717-787-6825
www.newpa.com
Our Mission: The Department of Community
and Economic Development (DCED) fosters
opportunities for businesses to grow and for
communiites to succeed and thrive in a global
economy. We strive to impove the quality of life
for Pennsylvania citizens while assuring transparency
and accountability in the expenditure of
public funds.
poSt proceSS llc..............................................1000
7478 Armstrong Rd
Manilus, NY 13104
315-427-9317
Post Process produces machines used in the
post processing of a wide range of additive
manufactured parts. Our first product, the 3P-2, is
designed to remove support from large envelope
FDM machines with a "no-touch" process. Other
products on display include a tumbler for finishing
FDM parts, a small envelope no-touch machine
and a "no-touch" support removal machine
for Polyjet parts. We will be taking orders for our
first machine, the 3P-2 at the Rapid show. Come
by and see our "no-touch"!
powder part ........................................................710
475 Wildwood Ave
Woburn Massachusetts 01801
781-937-5551
PowderPart is a manufacturing company,
which focuses on additive technologies and, in
particular, Selective Laser Melting. The facility
is equipped with Concept Laser’s machines.
PowderPart’s target markets are the medical
and aerospace sectors. PowderPart will work in
compliance with the international standards and
with a quality management system able to deal
with the requirements of the above-mentioned
industries. PowderPart is able to supply finished
components, with machined surfaces, where
necessary, as to guarantee the required dimensional
tolerances.
priSM engineering, inc ...................................910
2835 E Carson St Suite 203
Pittsburgh Pennsylvania 15203
888-441-9696
www.prismeng.com
Prism Engineering is the Mid-Atlantic’s largest
volume provider of CAD/CAM Solutions and
3D Prototype Printers. Major product offerings
include: SolidWorks ® , Mastercam, and Stratasys
3D Printers. Prism offers award-winning Training
and Support Services at its Certified Training
Centers, located in Pittsburgh, Philadelphia, Allentown,
PA, Baltimore, MD, and Lynchburg, VA.
www.prismeng.com
protocaM ..............................................................626
3848 Cherryville Rd
Northampton Pennsylvania 18067
610-261-9010 • 610-261-9350
www.protocam.com
ProtoCAM provides a unique blend of rapid
prototyping services, prototype development,
and manufacturing engineering consulting along
with deep domain expertise in stereolithography,
and other rapid prototyping techniques.
ptM&w induStrieS inc ....................................711
10640 Painter Ave
Santa Fe Spgs California 90670-4092
562-946-4511 • 562-941-4773
www.ptm-w.com
PTM&W Industries formulates and manufactures
urethane and epoxy systems for both display and
functional prototype parts. We make the toughest
rigid urethanes in the industry to replicate thermoplastic
materials, including products qualified
to UL94 V-0 fire-retardant specifications. Our
materials may be hand poured, vacuum cast or
machine dispensed. In addition, PTM&W makes
composite, tooling, and adhesive resin systems.
R
rapid product developMent group inc ...427
300 West Grand Avenue Suite 200
Escondido California 92025
619-270-1116 • 619-330-1850
www.RPDG.com
RPDG’s world-class services support your
new product development from prototyping to
complete production and contract manufacturing:
6/2013 – RAPID 61

EXHIBITORS
- Rapid Prototyping (CNC, SLA, Polyjet, SLS, FDM,
RTV, Sheetmetal) - Tooling (Rapid, Bridge, Production)
- Production (Injection molding, Die Casting,
Sheetmetal) - Short-Run Contract Manufacturing
RPDG is headquartered in San Diego, with offices
throughout North America and international facilities
in Mexico and China.
rapid prototype + manufacturing ..........302
33490 Pin Oak Pkwy
Avon Lake Ohio 44012
440-933-8850 • 440-933-7839
www.rpplusm.com
Product Design & 3D Printing: Taking ideas and
bringing them to life - Rapid Prototyping: Additive
Manufacturing - Fused Deposition Modeling- We
have all Stratasys machines - Polyjet- Objet Connex500
Machine - Secondary Processes - Vapor
Smoothing - Painting - Sanding - 3D Scanning
- Design Engineers - Design for manufacturability
- Developing new materials - Developing new
additive manufacturing processes
renishaw inc..................................... 411
5277 trillium Blvd
hoffman est illinois 60192-3602
847-286-9953 • 847-286-9974
www.renishaw.com
see ad in this issue
renishaw is a global company with core
skills in measurement, motion control,
spectroscopy and precision machining. we
develop innovative products that significantly
advance its customers’ operational
performance - from improving manufacturing
efficiencies and raising product quality, to
maximizing research capabilities and improving
the efficacy of medical procedures. see
us at booth #411. further information about the
renishaw group at www.renishaw.com
repliform ..............................................................508
1583 Sulphur Spring Rd Ste 104
Baltimore Maryland 21227-2574
410-242-5110 • 410-242-5227
www.repliforminc.com
RePliForm, Inc. provides a copper/nickel
coating to improve the properties of RP models.
Our RePliKote process adheres to most RP
resins and can tolerate high temperatures.
RePliKote serves as a protective barrier in
harmful environments, provides EMI shielding
and a coat of armor for structural reinforcement
to make your RP model functional. RePliForm
provides you with an enhanced part at a
reasonable cost with a quick turnaround.
rJ lee group inc .................................................808
350 Hochberg
Monroeville Pennsylvania 15146
724-325-1776 • 724-733-1799
www.rjlg.com
RJ Lee Group is an industry leader in Industrial
Forensics, providing comprehensive expertise
and materials characterization from the raw
material to final component. We work with our
clients to ensure appropriate material selection,
quality and specifications on a range of materials
- polymers/plastics, metals and ceramics.
roBotic solutions inc ....................................625
17685 W Lincoln Ave
New Berlin Wisconsin 53146-2120
262-786-3500 • 262-786-3501
www.roboticsolutionsinc.com
We pride ourselves on being expert robot integrators.
The success we’ve had at making this
all work is due to our machining, engineering,
and CAD/CAM experience. Our Robotic Milling
Systems famous for being constructed better
than any other companies in the industry. We are
continuously integrating our systems with the latest
in technology to keep current. Our customers
are creating excellent parts on our systems the
same week that the systems are installed.
roland dga corp. ...............................................725
1126 Dovercliff Way
Crystal Lake Illinois 60014
224-565-5210 • 815-477-8347
rudolph Bros & co ............................................325
6550 Oley Speaks Way
Canal Winchester Ohio 43110-8272
614-833-0707 • 614-833-0456
www.rudolphbros.com
Rudolph Bros. & Co. is committed to exceeding
our customers’ expectations by providing quality
products and services at competitive prices. The
philosophy of the company is to develop close,
mutually supportive business relationships to
help our customers discover new, more efficient
methods to solve their technical problems with
product design, development and manufacturing.
We’re a stocking distributor of mold making and
casting materials, release agents, and tooling
boards for prototyping.
S
scicon technologies corp ............................520
27525 Newhall Ranch Rd Ste 2
Valencia California 91355-4003
661-295-8630 • 661-295-6611
www.scicontech.com
Scicon Technologies Corporation is your Single
Source Rapid Prototyping and Manufacturing
Center. Since 1989, Scicon has been a premier
service bureau offering one-off parts, low-run
production, and complete assemblies: Stereolithography
(SLA ® ), Selective Laser Sintering
(SLS ® ), CNC 5-axis machining, RTV, Urethane
Castings, and Sciconís SciCast PMC TM (Precision
Metal Casting).
shapegraBBer inc .............................................320
1900 City Park Dr Ste 304
Ottawa Ontario K1J 1A3
Canada
613-247-1707 • 613-247-1707
www.shapegrabber.com
ShapeGrabber’s 3D scanners measure complex
parts quickly and accurately in minutes, not
hours. Unlike traditional methods that capture a
few points, ShapeGrabber captures the complete
surface information. Reduce scrap rates, slash
machine idle time and reduces inspection time.
Get out of the CMM queue: ShapeGrab It
silicones inc ........................................................809
PO Box 363 211 Woodbine St.
High Point North Carolina 27261-0363
336-886-5018 • 336-886-7122
www.silicones-inc.com
Manufacture RTV-2 silicones. Addition (platinum)
and condensation (tin) cured systems. Formulators
of our own silicone line (GI-1000) for over 35
years. Shore A hardnesses vary from gels to 75.
Custom formulations are available.
slm solutions na inc ......................................511
40000 Grand River Ave. Suite 503
Novi Michigan 48375
248-937-1112
www.slm-solutions.com
SLM Solutions NA inc. as a fully owned subsidiary
of the SLM Solutions GmbH from Germany
provides the whole range of rapid prototyping
products with a focus on additive manufacturing
equipment, especially Selective Laser Melting
Technologies.
sme ...........................................................................913
One SME Dr
Dearborn Michigan 48128-2408
800-733-3976 • 313-425-3412
www.sme.org
Stop by to find out how you can MEET / KNOW
/ GROW with SME! Through its many programs,
events, magazines, publications certifications
and online training division, Tooling U, SME
connects manufacturing practitioners to each
other, to the latest technologies and to the most
up-to-date manufacturing processes. SME has
members around the world and is supported by a
network of chapters and technical communities
so you can get involved both locally and in your
technical area of interest.
sme medical manufacturing
innovations .......................................................912
One SME Dr
Dearborn Michigan 48128-2408
800-733-3976 • 313-425-3412
www.sme.org
From manufacturing of end-use surgical devices
and customized implants, to bone scaffolds and
functioning organ replacements, additive manufacturing
is truly changing lives. Explore the MMI
center to see unique applications, meet medical
manufacturing leaders and hear more at the
Learning Lounge. Watch for information on how
to join us virtually for these discussions!
solid concepts inc ...........................................713
28309 Avenue Crocker
Valencia California 91355-1251
661-295-4411 • 661-295-6877
www.solidconcepts.com
Solid Concepts supplies rapid prototyping, shortrun
production, tooling and molding services
for all industries from aerospace and medical
to sports and entertainment. Capabilities in
PolyJet, Z-Corp 3D Color Prints, SLA, SLS, DMLS,
FDM, QuantumCast TM cast urethanes, CNC and
Composite prototypes and short run production
parts. Tooling and Molding expertise to bring
your project through to completion. ISO 9001 and
AS9100 certified.
steinBichler vision systems inc ...............324
46995 Five Mile Rd
Plymouth Michigan 48170-2486
734-927-1540 • 734-927-1549
www.steinbichler.com
Steinbichler Vision Systems, fully owned subsidiary
of Steinbichler Optotechnik, a worldwide
leading supplier of optical measuring technology.
62 sme.org/rapid

We develop and market precise measurement
systems with corresponding software solutions
for a wide range of applications. Our best in
class 3D digitizing products-COMET ® and T-scan
are operational in well-known companies.
Shearography system-ISIS is rapidly gaining
Defense, Aerospace, Research and Development
and Manufacturing customers worldwide.
StrataSyS Inc ................................... 604
7665 commerce Way
Eden Prairie Minnesota 55344-2001
952-937-3000 • 952-937-0070
www.stratasys.com
See ad in this issue
Stratasys Ltd. offers FDM ® and Polyjet ® -based
3D printers that produce parts directly from 3D
caD files or other 3D content. Stratasys makes
a range of systems for concept modeling, rapid
prototyping, and direct digital manufacturing.
the company’s 130 materials include over 120
photopolymers and 10 thermoplastics.
T
tct MagazInE .......................................................525
Carlton House Sandpiper Way
Chester CH4 9QE
United Kingdom
00441244680222 • 00441244671074
www.tctmagazine.com
TCT Magazine is THE magazine for additive
manufacturing (AM) and professional 3D printing.
TCT is part of the Rapid News AM and 3D Printing
Group, a global portfolio of AM and 3D printing
products that includes www.tctmagazine.
com and www.tctshow.com. It has a worldwide.
professional, BPA audited readership. In 2012 the
AM and 3D Printing Group launched www.prsnlz.
me, the hub for the 3D printing and personal
manufacturing community. We have been covering
AM in all forms for more than 20 years.
tEbIS aMErIca Inc ..............................................922
1742 Crooks Rd
Troy Michigan 48084-5501
248-524-0430 • 248-524-0434
www.tebis.com
Tebis CAD/CAM Tebis offers high-end CAD/
CAM systems for the automotive, consumer
and aerospace industries. Knowledge based
planning and manufacturing throughout the
product chain shortens production time and
increases quality, accuracy and safety while
guaranteeing quick ROI. Fast, precise, userfriendly
functionalities, from advanced die and
mold design to reverse engineering.
tEch caSt LLc .......................................................524
640 South Cherry Street
Myerstown Pennsylvania 17067-1511
717-866-9009 • 717-866-2369
www.techcastllc.com
Established foundry in 1977 - Investment Casting
Manufacture with an employee base of 100.
Manufacturing facility is 35,000 sq ft, air melt,
100% commercial investment cast foundry. Product
Distribution: NAFTA and Europe. Preferred
supplier of closed impellers for the military and
oil/gas industry, mission critical components
to support programs such as battlefield and
shipboard applications, i.e. submarines and light
armored combat vehicles. Large investment
castings up to 300 lbs.
thE tEchnoLogy houSE ....................................323
30555 Solon Industrial Pkwy
Solon Ohio 44139-4329
440-248-3025 • 440-248-3883
www.tth.com
The Technology House a leading provider of
product development/engineering and rapid
prototyping services including SLA, FDM, SLS,
cast urethane, metal castings, injection molding,
CNC machining & turning. We also offer
production volume manufacturing of injection
molded plastic, urethane, and metal mechanical
components. Our under-one-roof approach to
design, prototyping, and production allows you
to bring your concept to the market faster. We
serve the medical, aerospace, defense, energy,
and consumer markets.
thySSEnKruPP MatErIaLS
na aIn PLaStIcS DIvISIon ..............................624
1750 E Heights St
Madison Hts Michigan 48071-4235
248-356-4000 • 248-542-3920
www.thyssenkrupp.com
AIN Plastics, a Division of ThyssenKrupp Materials
NA is a supplier of Engineering, Industrial and
other highly specialized plastics materials. Our
inventory includes one of the broadest selections
of sheet and rod materials. AIN Plastisc is also
the Authorized distributor for DuPont Vespel. Our
specialized services include custom cutting to
cloe tolerances on all orders, customized inventory
solutions including just in time delivery and
application support.
V
vacucoat tEchnoLogIES .................................510
33575 Giftos Dr
Clinton Twp Michigan 48035-4212
586-791-1117 • 586-791-2143
www.vacucoat.com
VacuCoat Technologies is a custom vacuum
metallizer. VacuCoat provides vacuum metallizing
services for low volume production, rapid
prototypes, and one-off models. Some current industries
supplied include aerospace, automotive,
consumer goods, medical, and fiber optics. We
specialize in metallizing plastics, SLA, SLS, FDM,
and most other RP models, urethane castings,
and tooling board, and offer quick turn-around.
vISSEr PrEcISIon caSt .....................................923
6275 East 39th Avenue
Denver Colorado 80207
513-617-8386 • 303-454-1651
www.visserprecisioncast.com
Visser Precision Cast is the global leader in the
development of injection molding amorphous
metals. Liquidmetal casting is a hybrid of plastic
injection molding and die casting capable of
much higher geometry resolution and tolerances
compared to Metal Injection Molding(MIM). VPC
is very focused on being the complete supplier
in not just offering Liquidmetal, but also Direct
Metal Laser Sintering and Precision Machining.
voxELjEt tEchnoLogy gMbh .........................810
Paul-Lenz-Strasse 1
Friedberg 86316
Germany
+49 821 7483100 • +49 821 7483111
www.voxeljet.com
voxeljet operates on different fields: Service:
molds for casting, cast parts or plastic parts are
produced according to CAD-Data and customer
specifications. Machine manufacturer: industrial
3D printing solutions to professionals who search
highest productivity and reliability at low running
costs. The enormous building speed and the
large build volume ensure that these systems
are the right choice for the fast and economic
production of your prototypes and small batches.
W
WEnzEL aMErIca LtD .........................................327
46962 Liberty Drive
Wixom Michigan 48393-3693
248-295-4300 • 248-295-4301
www.wenzelamerica.com
Wenzel America Ltd is a wholly-owned
subsidiary of Wenzel Group of Germany. The
company sells and supports the full range
of Wenzel products including the range of
industrial CT scanners produced by Wenzel
Volumetrik. The exaCT range, offers machines
from low-cost bench-top systems to very
powerful models capable of scanning multimaterial
assemblies and aluminum castings.
In addition to selling the CT machines Wenzel
America offers CT scanning services.
WISconSIn PrEcISIon caStIng corP ..........806
W405 County Road L
East Troy Wisconsin 53120-2406
262-642-7307 • 262-642-4415
www.wisconsinprecision.com
WISCONSIN PRECISION, a leading manufacturer
of Rapid Prototype Metal Components and
production Investment Castings. Prototypes
delivered in 7-10 working days-no tooling
required. A proven method to prototype your new
product designs quickly and cost effectively.
Enjoy greater design freedom and alloy selection
to enhance the design and performance of your
components. Select from over a 150 different
non-ferrous and ferrous alloys. Parts weighing
up to 110 lbs. (20" x 22" x24") can be produced.
WtWh MEDIa .........................................................627
2019 Center St Ste 300
Cleveland Ohio 44113-2358
440-234-4531
www.makepartsfast.com
WTWH Media MakePartsFast - www.makepartsfast.com
Design World - www.designworldonline.com
Renewables with Windpower Engineering
& Development and Solar Power World For
more information contact us at: 440-234-4531
6/2013 – RAPID 63

Additive Manufacturing
Additive Manufacturing:
Going Mainstream
Photo courtesy Nike
In February, Nike Football debuted the Nike Vapor Laser Talon with a revolutionary 3D printed plate that will help football players perform
at their best. It is specifically designed to provide optimal traction on football turf and to help athletes maintain their “drive stance” longer.
2013: Trends, myths, and investments
in additive manufacturing
Terry Wohlers
Principal Consultant and President
Tim Caffrey
Associate Consultant
Wohlers Associates Inc.
Fort Collins, CO
Additive manufacturing is receiving unprecedented
attention from the mainstream
media, investment community, and national
governments around the world. This attention
reached a pinnacle when 3D printing was
mentioned by President Barack Obama in
his February 2013 State of the Union address. (Many, including
us, use the terms “additive manufacturing” and “3D printing”
interchangeably.) AM, just 25 years old and still a relatively
small industry, has completed a transformation from obscurity to
something that many can’t stop talking about.
64 sme.org/rapid

INDUSTRY
One of the top companies in the AM industry monitors the
number of articles on the subject. In 2011, about 1600 articles
were found. In 2012, that number ballooned to around 16,000—a
tenfold increase. 3D printing has also developed into a darling of
the crowd-funding world. Three of the top ten all-time Kickstarter
technology projects are 3D printers from Formlabs, Printrbot,
and RoBo 3D.
With all the attention 3D printing has attracted, it’s important
to point out where the technology works and where it is going.
Prototyping has been the technology’s biggest application, thus
the name rapid prototyping, and it remains a key category. The
fastest-growing application, however, is in the actual manufacturing
of parts for final products. In just 10 years, this important
application has grown from almost nothing to more than 28% of
the total global product and service revenues, according to our
research for Wohlers Report 2013. The manufacturing of final
parts, rather than prototyping, is where the manufacturing money
is, and it is the most significant part of AM’s future.
Morris Technologies Inc., a Cincinnati-based company with
21 metal powder bed fusion systems, has been a trailblazer in
developing complex and high-value metal parts made by additive
manufacturing. GE Aviation acquired Morris Technologies and
its sister company, Rapid Quality Manufacturing, in November
2012. Earlier in the year, GE announced its intention to produce
fuel injector assemblies for its next-generation LEAP jet engine by
additive manufacturing. The acquisition illustrates GE’s optimistic
view of AM, and essentially “locks up” Morris’s vast knowledge
and experience for GE only.
This is truly an exciting time for additive
manufacturing. The fast-growing industry
is enjoying unprecedented levels of
attention, interest and investment—
as well as hype—around the world.
GE Aviation also plans to use AM to produce the titanium
leading edges for the LEAP engine’s fan blades. Meanwhile,
German company EOS GmbH, a leading manufacturer of metal
powder bed fusion systems, estimates that 15,000 dental copings
are made in the company’s machines every day. A coping is the
metal structure for dental crowns and bridges. What’s more, an
estimated 80,000 acetabular (hip) cups have been manufactured
using electron beam melting powder bed fusion systems from
Sweden’s Arcam AB. These are standard, off-the-shelf products
that come in a range of sizes. More than 30,000 of these parts
have been implanted into patients.
The evolution of MYLON
frames by MYKITA began
with a new production
process, laser sintering, in
which a polyamide power
is turned into an object
layer by layer. MYKITA
has developed a complex
process that creates a
sophisticated finish in six
steps and gives the frames
a unique visual and tactile
appeal. MYKITA named
the new material MYLON
and has since won recognition for the development process in the
shape of the 2011 iF material award.
AM technologies are also making inroads into the consumer
products industry. The sporting goods company New Balance
is developing custom 3D-printed soles for its track spikes and
running shoes. In January, a professional runner wore 3D-printed
shoes for the first time at the New Balance Games in New York.
The cleat plate of Nike’s new Talon football shoe is manufactured
by 3D printing. The ultra-light Talon’s cleat plate was designed to
provide optimal traction and help athletes maintain their “drive
stance” while sprinting, according to Nike. Two manufacturers of
eyeglasses, Mykita and pq, offer products with 3D-printed nylon
frames. The Corbs line from pq, designed by Ron Arad, features
one-piece frames with hinging action created by a series of
scores in the material.
Fact vs. Fiction
Despite many examples of growth and progress, a considerable
amount of hype surrounds AM, and many myths and misconceptions
associated with the technology have developed.
Myth #1: AM is a low-labor content, “pushbutton” technology.
While it’s true that AM often runs overnight in lights-out operations,
a lot of work occurs before and after the actual production
of the parts. Data needs to be prepared at the front end,
which may require CAD expertise, the repair of the models, and
optimization of support structures. (Most AM systems require
that structures are designed to support overhanging features and
other areas of parts.) Build parameters, such as layer thickness,
temperature, build speed, and a number of other options may
Photo courtesy Mykita
6/2013 – RAPID 65

Additive Manufacturing
need to be adjusted for a particular part, group of parts, or type
of material. Thermal AM processes require pre-build chamber
heating and post-build chamber cooling and this can take hours,
even tens of hours, for large parts and large build volumes. And
postprocessing steps, including the removal of support material,
stress relief, and finishing, can be quite labor intensive.
Myth #2: Additive manufacturing is fast. AM systems build
parts by depositing, fusing, curing, or laminating consecutive layers
of material. These layers are typically 0.001 to 0.010" (0.025–
0.254 mm) in thickness, so parts often require thousands of layers.
Defining the perimeter and solidifying the area of each layer for
large volumes can be quite time consuming. The period between
layers also adds time. Processes that operate with a heated build
chamber take time for preheating and cooling cycles. With all the
required steps, some jobs take several days.
Myth #3: AM is greener than conventional manufacturing. At
one time, many hoped that one-off, distributed manufacturing
would result in more energy-efficient products. However, the
studies completed to date—mostly in Europe—do not necessarily
support this theory. AM processes consume more electrical
energy per unit of mass of material produced compared to conventional
processes. When combined with new design capabilities,
less material, fewer parts in inventory, and the elimination
of tooling, the picture improves. This is especially true when
compared to waste-intensive processes, such as CNC machining.
In the aerospace industry, the environmental benefits of AMenabled
weight reduction are clear, because weight reduction
results in substantial fuel savings. We know now that assessing
the environmental benefits of AM is a very complex exercise that
requires an analysis of the entire life cycle of a product, from raw
material processing to the product’s end of life. The industry will
need to embark on thorough, cradle-to-grave assessments of
AM’s energy efficiency.
AM systems build parts by depositing,
fusing, curing, or laminating consecutive
layers of material. These layers are
typically 0.001 to 0.010" in thickness, so
parts often require thousands of layers.
Myth #4: AM systems can produce anything. The adage “if
you can design it, you can build it” is generally true, as most AM
processes are blind to the complexity of a part and can successfully
build shapes that cannot be fabricated easily or at all using
conventional methods of manufacturing. However, AM processes
also have limitations. One is minimum wall thickness. Another is
the requirement for supports and anchors on down-facing surfaces,
which can be difficult or sometimes impossible to remove.
Material that is trapped in internal channels can also be difficult
or impossible to remove, and the size of the internal channels
impact the degree of difficulty in removing unwanted material.
Global athletic leader
New Balance in March
announced a significant
advancement in the use of
3D printing to customize
high performance
products for athletes. At
the New Balance Games
in January 2013, Team
New Balance athlete,
Jack Bolas, became the
first-ever track athlete to
compete in customized, 3D
printed plates.
Myth #5: With AM, it’s just as efficient to build one part at a
time as it is to build many. Depending on the process, packing
the build volume with parts makes a significant difference in
the per-part build time, cost, and energy consumed. AM comes
with economy of scale, especially with powder bed processes,
where the entire build volume can be filled, and stacked, with
many parts. A similar myth is that it’s just as efficient to make 50
custom parts as it is to make 50 copies of a single part. In reality,
while build time and expense may be the same, the pre-build file
preparation and post-build part finishing may be considerably
more time-consuming when each part is unique.
Myth #6: AM systems and materials are inexpensive. It’s true
that some 3D printers for hobbyists and do-it-yourselfers are
inexpensive. The least expensive 3D printer, the MakiBox, lists
for $200. The list price of Concept Laser’s X line 1000R metal AM
system in Europe is €1.4 million. Generally, industrial AM systems
are more expensive than CNC machining centers. And materials
are far more expensive. Plastic materials for AM can be 53 to 104
times more expensive than plastic materials for injection molding.
Myth #7: AM will replace conventional manufacturing. AM
has disrupted and forever changed several niche manufacturing
applications, including in-the-ear hearing aids, dental restorations,
orthopedic implants, orthodontics, and environmental
control system ducting for aircraft. However, AM will not displace
Photo courtesy New Balance
66 sme.org/rapid

conventional manufacturing methods for high-volume, lowcomplexity
parts any time soon. Think of common mass-produced rise of local 3D print shops, similar to today’s document printing
change their behavior. The more likely development will be the
items, such as injection-molded stadium seats, trash cans, and service companies, and online transactions for parts and products,
similar to the way many of us use Amazon and other sites to
disposable drinking cups, or the ubiquitous 12-ounce aluminum
beverage containers. These products will continue to be made by purchase products.
conventional methods because it is much
faster and more cost-effective to do so.
Myth #8: AM can print guns. Of all the
media attention AM has drawn, the most
unsavory has been the hype around the 3D
printing of guns. Here are the facts: some
noncritical parts of a semiautomatic rifle
were made on a 3D printer. The gun broke
after it was fired six times, which confirms
the premise that a plastic 3D printed firearm
does not hold up to the heat, impact,
and ballistic energy of rapid firing. The gun
is more of a danger to the person shooting
it than to anyone else. The US is the most
heavily armed country on the planet, with
about a third of the world’s guns, so market
demand for a new way to manufacture
guns simply does not exist. Also, we know
of many ways (e.g., basic machine shop
tools and materials) that are better for
making gun parts. The focus on 3D printing
guns is a red herring, and the media and
AM industry would be well served to move
on to more productive subjects.
Myth #9: Every household will own
a 3D printer. This assumption draws on
the parallel between personal computers
and 3D printers. There was certainly a
time when the claim that every household
would have a computer was met
with skepticism. However, the analogy
for 3D printers simply does not hold up.
Before computers, people would write,
publish, communicate with others, present
information, manage documents, listen to
music, organize photos, and do accounting
and research. People continue to do
these things, but now with the support of
computers. Most people are not designers
of products or inventors, so the widespread
availability of 3D printers will not
Designed for production
The Arcam Q10 represents the 3rd generation EBM
technology. It is a manufacturing equipment specifically
designed for cost-eff
icient production of components
with high complexity and fine detail, such as
ort
hopedic implants.
Key Features:
• Arcam LayerQam for
build verification
• Latest generation EB gun
• Closed powder handling
www.arcam.com
See us at Booth #821
6/2013 – RAPID 67

Additive Manufacturing
Photo courtesy New Balance
A Vibrant Future
Despite the hype and half truths, additive manufacturing is
gaining steam around the world. In fact, a number of national
governments have committed sizable resources to the development
and advancement of the technology.
In August 2012, the National Additive Manufacturing Innovation
Institute (NAMII) was created as the pilot institute for the
National Network for Manufacturing Innovation (NNMI). The
NNMI is a proposed investment of $1 billion in up to 15 institutes
across the US, each serving as a regional hub of advanced
manufacturing and innovation. NAMII was launched with $30
million in funding from the Departments of Defense, Energy, and
Commerce, and the National Science Foundation. Industrial and
academic partners in NAMII have more than matched this initial
investment with $40 million in cash and in-kind contributions. In
March of this year, NAMII announced awards for seven applied
research and development projects in AM, totaling more than $9
million in funding. A second call for R&D projects is expected in
June of this year. As of mid April, 76 organizations across the US
had become members of NAMII.
The government of Singapore announced plans to invest an
impressive $403 million over five years in advanced manufacturing
and 3D printing technologies. The investment is part of the
government’s Future of Manufacturing program, intended to get
manufacturers to embrace disruptive technologies and help the
country’s competitiveness with neighboring countries. As part of
the program, the government expects to consider building a 3D
printing industry ecosystem.
For the production of the custom plates, New Balance uses laser
sintering to convert powder materials into solid cross-sections, layer
by layer using a laser. SLS printing enables the customization process
by allowing for complex designs that could not be achieved through
traditional manufacturing methods.
The central government of China plans to pour about $240
million into AM research, development, and commercialization.
The emphasis on AM is expected to last seven years, but the
funding is for the first three, which means each funded project
must become self-sustaining after three years. The funding
is part of a concerted effort in China to develop a high-tech
industrial infrastructure, complete with universities, research
institutes, and advanced manufacturing capabilities. Provincial
and city governments are expected to invest even more money
and resources into AM.
German company EOS GmbH, a leading manufacturer of metal powder
bed fusion systems, estimates that 15,000 dental copings are made in the
company’s machines every day. A coping is the metal structure for dental
crowns and bridges.
The European Union and many national governments in
Europe are funding projects on additive manufacturing. The
European Space Agency, for example, recently launched a 4.5-
year, €1.88 million project titled Additive Manufacturing Aiming
Towards Zero Waste and Efficient Production of High-Tech
Metal Products. The project seeks to produce defect-free metal
parts that measure up about 78" (1981 mm) in size, with close
to zero waste. Another objective is to reduce cost by 50% for
finished parts, compared to traditional processing. The parts
will be for the aeronautics, space, automotive, nuclear fusion,
and tooling industries.
This is truly an exciting time for additive manufacturing. The
fast-growing industry is enjoying unprecedented levels of attention,
interest and investment—as well as hype—around the
world. With so much being published on the subject, it can be
difficult to maintain an objective perspective on AM’s importance
and future. Despite the misinformation, misconceptions, and uncertain
future, AM is poised to some day become one of the most
valued forms of manufacturing ever. RP
Photo courtesy Smith Dentistry
68 sme.org/rapid

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PRODUCTS
Advanced Materials
Arcam AB .........................................................821
Directed Manufacturing .....................................409
DSM Somos ..........................................................421
Erasteel .................................................................726
Fabrisonic LLC ......................................................807
Harvest Technologies .........................................312
Innovative Polymers Inc .....................................812
Optomec Inc .........................................................903
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Renishaw Inc ...................................................411
RJ Lee Group Inc .................................................808
Visser Precision Cast ..........................................923
WTWH Media ......................................................627
Associations
National Additive Manufacturing
Innovation Institute .......................................... 902
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Pennsylvania Department of Community
& Economic Development .............................1001
SME .......................................................................913
CAD/CAM
ACTech North America.......................................827
American Precision Prototyping LLC ...............521
Arcam AB .........................................................821
Aristo Cast Inc .....................................................811
Boundary Systems ............................................. 304
Delcam ..................................................................306
Direct Dimensions Inc ........................................326
Directed Manufacturing .....................................409
EOS GmbH - Electro Optical Systems ..............412
Fabrisonic LLC ......................................................807
Fathom ...................................................................424
Incodema Inc .......................................................311
Laser Reproductions ...........................................426
Materialise USA ...........................................502,403
Medical Modeling Inc ........................................909
Nikon Metrology Inc ...........................................824
Powder Part .........................................................710
Prism Engineering, Inc .......................................910
Rapid Product Development Group Inc ...........427
Robotic Solutions Inc ..........................................625
Tebis America Inc................................................922
WTWH Media ......................................................627
Castings
American Precision Prototyping LLC ...............521
Aristo Cast Inc .....................................................811
Armstrong Mold Corp .........................................308
Citim Gmbh ...........................................................406
Harvest Technologies .........................................312
Incodema Inc .......................................................311
Met-L-Flo Inc ........................................................527
Rapid Product Development Group Inc ...........427
Scicon Technologies Corp .................................520
Silicones Inc .........................................................809
Steinbichler Vision Systems Inc .......................324
Tech Cast LLC .......................................................524
The Technology House .......................................323
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
Wisconsin Precision Casting Corp ...................806
CNC Systems & Software
Aerotech Inc ........................................................927
Aristo Cast Inc .....................................................811
Laser Reproductions ...........................................426
Nikon Metrology Inc ...........................................824
Prism Engineering, Inc .......................................910
Robotic Solutions Inc ..........................................625
Tebis America Inc................................................922
Composites, Vacuum
Forming Systems
Arcam AB .........................................................821
Solid Concepts Inc ..............................................713
Compression Molding
Motorola Solutions .............................................621
Computer-Aided Engineering
(CAE)
Aristo Cast Inc .....................................................811
Capture 3D Inc .....................................................709
Layerwise NV .......................................................526
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Prism Engineering, Inc .......................................910
WTWH Media ......................................................627
Curing Equipment
M. Braun, Inc .......................................................921
Design of Experiments (DOE)
Harvest Technologies .........................................312
Layerwise NV .......................................................526
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Education & Training
Services & Institutions
Boundary Systems ............................................. 304
National Additive Manufacturing
Innovation Institute .......................................... 902
Penn State Center for Innovative Materials
Pennsylvania Department of Community
& Economic Development .............................1001
Processing through Direct
Digital Deposition ..............................................907
Renishaw Inc ...................................................411
SME Medical Manufacturing Innovations ......912
SME .......................................................................913
Engineering Services
ACTech North America.......................................827
Capture 3D Inc .....................................................709
Cideas Inc .........................................................620
Direct Dimensions Inc ........................................326
EFESTO LLC ..........................................................920
eQuality Tech Inc .................................................322
Fathom ...................................................................424
Layerwise NV .......................................................526
M. Braun, Inc .......................................................921
Materialise USA ...........................................502,403
Medical Modeling Inc ........................................909
National Additive Manufacturing
Innovation Institute .......................................... 902
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Prism Engineering, Inc .......................................910
rapid prototype + manufacturing ......................302
Scicon Technologies Corp .................................520
Tebis America Inc................................................922
The Technology House .......................................323
Wenzel America Ltd ............................................327
Finishing & Coating
American Precision Prototyping LLC ...............521
Cideas Inc .........................................................620
EFESTO LLC ..........................................................920
Harvest Technologies .........................................312
Incodema Inc .......................................................311
Met-L-Flo Inc ........................................................527
Microtek Finishing ...............................................420
Post Process LLC ...............................................1000
Rapid Product Development Group Inc ...........427
RePliForm ..............................................................508
Solid Concepts Inc ..............................................713
Stratasys Inc ........................................................604
Foamed Plastics, Molders
Armstrong Mold Corp .........................................308
Steinbichler Vision Systems Inc .......................324
Geometric Dimensioning
& Tolerancing (GD&T)
Steinbichler Vision Systems Inc .......................324
Injection Modling Equipment
EOS GmbH - Electro Optical Systems ..............412
Laser Reproductions ...........................................426
Inspection Systems
& Equipment
Aerotech Inc ........................................................927
Capture 3D Inc .....................................................709
CGI 3D Scanning ..................................................407
Direct Dimensions Inc ........................................326
eQuality Tech Inc .................................................322
GoMeasure3D ......................................................307
Nikon Metrology Inc ...........................................824
North Star Imaging Inc .......................................321
Prism Engineering, Inc .......................................910
Renishaw Inc ...................................................411
ShapeGrabber Inc ...............................................320
Steinbichler Vision Systems Inc .......................324
Wenzel America Ltd ............................................327
Lasers & Related Equipment
Aerotech Inc ........................................................927
Direct Dimensions Inc ........................................326
DM3D Technology LLC........................................906
eQuality Tech Inc .................................................322
Fathom ...................................................................424
GoMeasure3D ......................................................307
Laser Reproductions ...........................................426
Nikon Metrology Inc ...........................................824
Optomec Inc .........................................................903
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Renishaw Inc ...................................................411
70 sme.org/rapid

ShapeGrabber Inc ...............................................320
Steinbichler Vision Systems Inc .......................324
Machine Tooling
Fabrisonic LLC ......................................................807
Powder Part .........................................................710
Renishaw Inc ...................................................411
Stratasys Inc ........................................................604
WTWH Media ......................................................627
Measuring Tools
& Equipment
Capture 3D Inc .....................................................709
CGI 3D Scanning ..................................................407
Delcam ..................................................................306
Direct Dimensions Inc ........................................326
FARO Technologies Inc ......................................309
GoMeasure3D ......................................................307
Nikon Metrology Inc ...........................................824
Prism Engineering, Inc .......................................910
Renishaw Inc ...................................................411
ShapeGrabber Inc ...............................................320
Steinbichler Vision Systems Inc .......................324
WTWH Media ......................................................627
Metals
Armstrong Mold Corp .........................................308
Concept Laser GmbH ..........................................710
Directed Manufacturing .....................................409
DM3D Technology LLC........................................906
EFESTO LLC ..........................................................920
EOS GmbH - Electro Optical Systems ..............412
Erasteel .................................................................726
Fabrisonic LLC ......................................................807
GPI Prototype & Manufacturing
Services Inc .......................................................707
Harvest Technologies .........................................312
Incodema Inc .......................................................311
Layerwise NV .......................................................526
Medical Modeling Inc ........................................909
Optomec Inc .........................................................903
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Powder Part .........................................................710
RJ Lee Group Inc .................................................808
Scicon Technologies Corp .................................520
SLM Solutions NA inc .........................................511
Solid Concepts Inc ..............................................713
Visser Precision Cast ..........................................923
Milling
C&A Tool Engineering Inc ..................................823
Citim Gmbh ...........................................................406
Delcam ..................................................................306
Harvest Technologies .........................................312
Incodema Inc .......................................................311
Robotic Solutions Inc ..........................................625
Scicon Technologies Corp .................................520
The Technology House .......................................323
Visser Precision Cast ..........................................923
Mold, Tool & Die Design
Aristo Cast Inc .....................................................811
C&A Tool Engineering Inc ..................................823
Delcam ..................................................................306
EOS GmbH - Electro Optical Systems ..............412
Ex One Company ..................................................704
GPI Prototype & Manufacturing
Services Inc .......................................................707
Layerwise NV .......................................................526
Motorola Solutions ..............................................621
Prism Engineering, Inc .......................................910
Rapid Product Development Group Inc ...........427
Steinbichler Vision Systems Inc .......................324
Stratasys Inc ........................................................604
Tebis America Inc................................................922
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
Molders
Armstrong Mold Corp .........................................308
GPI Prototype & Manufacturing
Services Inc .......................................................707
The Technology House .......................................323
Molding Accessories
GPI Prototype & Manufacturing
Services Inc .......................................................707
Innovative Polymers Inc .....................................812
Renishaw Inc ...................................................411
Rudolph Bros & Co ..............................................325
Silicones Inc .........................................................809
SLM Solutions NA inc .........................................511
Moldmaking Services
American Precision Prototyping LLC ...............521
Aristo Cast Inc .....................................................811
Armstrong Mold Corp .........................................308
C&A Tool Engineering Inc ..................................823
GPI Prototype & Manufacturing
Services Inc .......................................................707
Harvest Technologies .........................................312
Laser Reproductions ...........................................426
Motorola Solutions ..............................................621
Rapid Product Development Group Inc ...........427
SLM Solutions NA inc .........................................511
Steinbichler Vision Systems Inc .......................324
The Technology House .......................................323
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
Multitasking Machines
Aerotech Inc ........................................................927
Optomec Inc .........................................................903
Part Designing
CGI 3D Scanning ..................................................407
Cideas Inc .........................................................620
Ex One Company ..................................................704
GPI Prototype & Manufacturing
Services Inc .......................................................707
Laser Reproductions ...........................................426
Layerwise NV .......................................................526
Optomec Inc .........................................................903
rapid prototype + manufacturing ......................302
Scicon Technologies Corp .................................520
The Technology House .......................................323
voxeljet technology GmbH .................................810
Patternmaking
American Precision Prototyping LLC ...............521
Cideas Inc .........................................................620
Citim Gmbh ...........................................................406
Ex One Company ..................................................704
Met-L-Flo Inc ........................................................527
Rapid Product Development Group Inc ...........427
Robotic Solutions Inc ..........................................625
Steinbichler Vision Systems Inc .......................324
voxeljet technology GmbH .................................810
Plastic Products
AFINIA ...................................................................310
American Precision Prototyping LLC ...............521
Cideas Inc .........................................................620
Directed Manufacturing .....................................409
EOS GmbH - Electro Optical Systems ..............412
eQuality Tech Inc .................................................322
Incodema Inc .......................................................311
Met-L-Flo Inc ........................................................527
Rapid Product Development Group Inc ...........427
rapid prototype + manufacturing ......................302
SLM Solutions NA inc .........................................511
Solid Concepts Inc ..............................................713
The Technology House .......................................323
voxeljet technology GmbH .................................810
Polyurethane Materials
& Systems
BJB Enterprises Inc ............................................720
Directed Manufacturing .....................................409
Innovative Polymers Inc .....................................812
PTM&W Industries Inc .......................................711
Rudolph Bros & Co ..............................................325
Prototype & Short Run Parts
AFINIA ...................................................................310
American Precision Prototyping LLC ...............521
Aristo Cast Inc .....................................................811
Armstrong Mold Corp .........................................308
C&A Tool Engineering Inc ..................................823
Cideas Inc .........................................................620
Citim Gmbh ...........................................................406
Direct Dimensions Inc ........................................326
Directed Manufacturing .....................................409
DM3D Technology LLC........................................906
DSM Somos ..........................................................421
EOS GmbH - Electro Optical Systems ..............412
eQuality Tech Inc .................................................322
Ex One Company ..................................................704
Fabrisonic LLC ......................................................807
Fathom ...................................................................424
GPI Prototype & Manufacturing
Services Inc .......................................................707
Harvest Technologies .........................................312
Incodema Inc .......................................................311
InTech Industries Inc ..........................................924
Laser Reproductions ...........................................426
Layerwise NV .......................................................526
Met-L-Flo Inc ........................................................527
Motorola Solutions ..............................................621
Optomec Inc .........................................................903
Protocam ..............................................................626
Rapid Product Development Group Inc ...........427
rapid prototype + manufacturing ......................302
RePliForm ..............................................................508
Scicon Technologies Corp .................................520
SLM Solutions NA inc .........................................511
Solid Concepts Inc ..............................................713
Stratasys Inc ........................................................604
The Technology House .......................................323
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
Wisconsin Precision Casting Corp ...................806
Prototyping Services
AFINIA ...................................................................310
American Precision Prototyping LLC ...............521
Aristo Cast Inc .....................................................811
Armstrong Mold Corp .........................................308
Boundary Systems ............................................. 304
C&A Tool Engineering Inc ..................................823
Cideas Inc .........................................................620
Citim Gmbh ...........................................................406
Directed Manufacturing .....................................409
6/2013 – RAPID 71

PRODUCTS
EOS GmbH - Electro Optical Systems ..............412
eQuality Tech Inc .................................................322
Ex One Company ..................................................704
Fathom ...................................................................424
FineLine Prototyping ...........................................721
GPI Prototype & Manufacturing
Services Inc .......................................................707
Harvest Technologies .........................................312
Incodema Inc .......................................................311
InTech Industries Inc ..........................................924
Laser Reproductions ...........................................426
Layerwise NV .......................................................526
Medical Modeling Inc ........................................909
Met-L-Flo Inc ........................................................527
Motorola Solutions ..............................................621
Prism Engineering, Inc .......................................910
Protocam ..............................................................626
Rapid Product Development Group Inc ...........427
rapid prototype + manufacturing ......................302
RePliForm ..............................................................508
Scicon Technologies Corp .................................520
SLM Solutions NA inc .........................................511
Solid Concepts Inc ..............................................713
Stratasys Inc ........................................................604
The Technology House .......................................323
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
Wisconsin Precision Casting Corp ...................806
Publications
Manufacturing Engineering Magazine ............913
Penn State Center for Innovative Materials
Processing through Direct
Digital Deposition ..............................................907
Society of Manufacturing Engineers ...............913
TCT Magazine ......................................................525
WTWH Media ......................................................627
Rapid Prototyping
Machine & Processes
ACTech North America.......................................827
Aerotech Inc ........................................................927
AFINIA ...................................................................310
Arcam AB .........................................................821
Boundary Systems ............................................. 304
C&A Tool Engineering Inc ..................................823
Cideas Inc .........................................................620
Citim Gmbh ...........................................................406
Concept Laser GmbH ..........................................710
Delta Micro Factory Corp ...................................820
Directed Manufacturing .....................................409
DSM Somos ..........................................................421
EFESTO LLC ..........................................................920
EnvisionTEC Inc ...................................................402
EOS GmbH - Electro Optical Systems ..............412
eQuality Tech Inc .................................................322
Ex One Company ..................................................704
Fathom ...................................................................424
GPI Prototype & Manufacturing
Services Inc .......................................................707
Harvest Technologies .........................................312
Incodema Inc .......................................................311
Laser Reproductions ...........................................426
Materialise USA ...........................................502,403
Mcor Technologies .............................................802
Medical Modeling Inc ........................................909
Met-L-Flo Inc ........................................................527
Motorola Solutions ..............................................621
Nikon Metrology Inc ...........................................824
Optomec Inc .........................................................903
Powder Part .........................................................710
Prism Engineering, Inc .......................................910
Protocam ..............................................................626
Renishaw Inc ...................................................411
Robotic Solutions Inc ..........................................625
SLM Solutions NA inc .........................................511
Solid Concepts Inc ..............................................713
Stratasys Inc ........................................................604
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
WTWH Media ......................................................627
Rapid Tooling
AFINIA ...................................................................310
American Precision Prototyping LLC ...............521
Aristo Cast Inc .....................................................811
Armstrong Mold Corp .........................................308
C&A Tool Engineering Inc ..................................823
Citim Gmbh ...........................................................406
Concept Laser GmbH ..........................................710
Delta Micro Factory Corp ...................................820
Directed Manufacturing .....................................409
DM3D Technology LLC........................................906
EOS GmbH - Electro Optical Systems ..............412
Ex One Company ..................................................704
Fathom ...................................................................424
GPI Prototype & Manufacturing
Services Inc .......................................................707
Incodema Inc .......................................................311
InTech Industries Inc ..........................................924
Laser Reproductions ...........................................426
Layerwise NV .......................................................526
Met-L-Flo Inc ........................................................527
Motorola Solutions ..............................................621
Rapid Product Development Group Inc ...........427
rapid prototype + manufacturing ......................302
Rudolph Bros & Co ..............................................325
Silicones Inc .........................................................809
SLM Solutions NA inc .........................................511
Solid Concepts Inc ..............................................713
Stratasys Inc ........................................................604
The Technology House .......................................323
Visser Precision Cast ..........................................923
voxeljet technology GmbH .................................810
Reverse Engineering
ACTech North America.......................................827
Aristo Cast Inc .....................................................811
Capture 3D Inc .....................................................709
CGI 3D Scanning ..................................................407
Cideas Inc .........................................................620
AD INDEX
Delcam ..................................................................306
Direct Dimensions Inc ........................................326
eQuality Tech Inc .................................................322
Ex One Company ..................................................704
GoMeasure3D ......................................................307
Materialise USA ...........................................403,502
Nikon Metrology Inc ...........................................824
rapid prototype + manufacturing ......................302
Renishaw Inc ...................................................411
ShapeGrabber Inc ...............................................320
Steinbichler Vision Systems Inc .......................324
Tebis America Inc................................................922
Wenzel America Ltd ............................................327
Software, Supplies
& Services
Aerotech Inc ........................................................927
Boundary Systems ............................................. 304
Capture 3D Inc .....................................................709
Delcam ..................................................................306
Direct Dimensions Inc ........................................326
eQuality Tech Inc .................................................322
Materialise USA ...........................................502,403
Nikon Metrology Inc ...........................................824
Prism Engineering, Inc .......................................910
Renishaw Inc ...................................................411
WTWH Media ......................................................627
Solid Modeling
AFINIA ...................................................................310
American Precision Prototyping LLC ...............521
Cideas Inc .........................................................620
Delcam ..................................................................306
Direct Dimensions Inc ........................................326
EFESTO LLC ..........................................................920
eQuality Tech Inc .................................................322
Fathom ...................................................................424
GoMeasure3D ......................................................307
Scicon Technologies Corp .................................520
Vacuum Systems
Aerotech Inc ........................................................927
Arcam AB .........................................................821
Innovative Polymers Inc .....................................812
M. Braun, Inc .......................................................921
SLM Solutions NA inc .........................................511
American Foundry Society.................................................................................................. 33
Arcam AB............................................................................................................................... 67
Cideas Inc .....................................................................................................................Cover 4
Design World ......................................................................................................................... 19
Desktop Engineering Magazine ......................................................................................... 69
MachineTools.com ............................................................................................................... 18
Medical Design Magazine .................................................................................................... 9
NAMII (NCDMM).........................................................................................................Cover 2
Renishaw Inc........................................................................................................................... 2
Manufacturing Engineering Media ..........................................................................Cover 3
TCT Magazine ....................................................................................................................... 17
Wohlers Associates Inc ...................................................................................................... 13
72 sme.org/rapid

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