Rapid prototyping is a computer program that constructs three-dimensional models of work derived from a Computer Aided Design (CAD) drawing. With the use of rapid prototyping, one can quickly and easily turn product designs into physical samples. The creation of physical samples through rapid prototyping is achieved through Adobe Portable Document Format (PDF) and CAD formats, as well as through cross-functional teams and integration. Rapid prototyping was first introduced to the market in 1987, after it was developed with the help of stereo lithography. Today, rapid prototyping is also known as solid freeform fabrication, 3-dimensional printing, freeform fabrication, and additive fabrication. The manufacturing process of rapid prototyping can produce automatic construction of physical models with 3-dimensional printers, stereo-lithography machines, and even laser sintering systems. Using a CAD drawing to create a physical prototype is quite simple for the user. First, the machine reads the data from the provided CAD drawing. Next, the machine lays a combination of liquid or powdered material in successive layers. The materials used in rapid prototyping are usually plastics, ceramics, wood-like paper, or metals such as stainless steel and titanium. With rapid prototyping, each layer is built to match the virtual cross section taken from the CAD model. Therefore, the final model is built up gradually with the help of these cross sections. Finally, the cross sections are either glued together or fused with a laser. The fusing of the model automatically creates its final shape. Rapid prototyping is necessary for those who want to create models for clients, such as architects and engineers. Rapid prototyping can reduce the design cycle time, allowing multiple tests to be performed on the design at a low cost. This is because each prototype can be completed within days or hours, rather than taking several weeks. With the help of rapid prototyping, all of these tests can be performed well before beginning volume production. In addition to engineers and architects, other professionals benefit from rapid prototyping, such as surgeons, artists, and archaeologists. Taken from wisegeek.com What is rapid prototyping?

Stereolithography Stereolithography is the most widely used rapid prototyping technology. Stereolithography builds plastic parts or objects a layer at a time by tracing a laser beam on the surface of a vat of liquid photopolymer. This class of materials, originally developed for the printing and packaging industries, quickly solidifies wherever the laser beam strikes the surface of the liquid. Once one layer is completely traced, it's lowered a small distance into the vat and a second layer is traced right on top of the first. The self-adhesive property of the material causes the layers to bond to one another and eventually form a complete, three- dimensional object after many such layers are formed.

Fused Deposition Modeling FDM is the second most widely used rapid prototyping technology, after stereolithography. A plastic filament is unwound from a coil and supplies material to an extrusion nozzle. The nozzle is heated to melt the plastic and has a mechanism which allows the flow of the melted plastic to be turned on and off. The nozzle is mounted to a mechanical stage which can be moved in both horizontal and vertical directions. As the nozzle is moved over the table in the required geometry, it deposits a thin bead of extruded plastic to form each layer. The plastic hardens immediately after being squirted from the nozzle and bonds to the layer below. The entire system is contained within a chamber which is held at a temperature just below the melting point of the plastic.

Three dimensional printing was developed at MIT. It's often used as a direct manufacturing process as well as for rapid prototyping. The process starts by depositing a layer of powder object material at the top of a fabrication chamber. To accomplish this, a measured quantity of powder is first dispensed from a similar supply chamber by moving a piston upward incrementally. The roller then distributes and compresses the powder at the top of the fabrication chamber. The multi-channel jetting head subsequently deposits a liquid adhesive in a two dimensional pattern onto the layer of the powder which becomes bonded in the areas where the adhesive is deposited, to form a layer of the object. Once a layer is completed, the fabrication piston moves down by the thickness of a layer, and the process is repeated until the entire object is formed within the powder bed. After completion, the object is elevated and the extra powder brushed away leaving a "green" object. No external supports are required during fabrication since the powder bed supports overhangs. Three Dimensional Printing