The system was developed under a Phase II Small Business Innovative Research (SBIR) contract with NASA's Marshall Space Flight Center, Alabama, to produce precision prototype patterns for aerospace tooling applications.

Dubbed "Big Foot" during the development phase, the Rapid PatternMaker can produce high precision, three-dimensional tooling patterns as large as one cubic foot.

Al Hastbacka of Sanders, presented the accuracy test results of the Rapid PatternMaker at the NASA Materials and Fabrication Techniques Workshop held on March 29, at Langley, VA. Mr. Hastbacka said "the Rapid PatternMaker accuracy measurements with an average error of 0.02 mm are a factor of two better when compared with the nearest test pattern out of a field of fifteen world competitor entries in tests conducted at the University of Tokyo". He also said, "the enhanced performance of the Rapid PatternMaker system is achieved by incorporating precision bearings, linear encoders, and advanced motion control hardware and software". The Rapid ToolMaker is priced at $200,000 and initial deliveries of Beta units will begin in August of this year.

The Rapid PatternMaker system is targeted for high precision, dimensionally accurate, tooling applications in the aerospace, automotive, industrial and consumer market segments. It has excellent potential for medical and microelectronics applications where accuracy, fine features and smooth surface finish are required.

Sanders Design International, founded in 1982, is headquartered in Wilton, NH and is engaged primarily in advanced commercial and military research and development activities. SDI conducts development of precision rapid prototyping equipment for a variety of industries including medical, aerospace, electronics, automotive, tool and die, plastics, jewelry and consumer products. SDI also conducts layered fabrication of highly accurate patterns as a service bureau operation.

Rapid Prototyping Overview

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