A note from Brian Sabart …
the evolution of materials in rapid prototyping

Brian Sabart RedEye

Deciding what material to use for your project is probably the most important decision you make. The testing or usability considerations undoubtedly determine the mechanical properties of the material, whether it is heat resistance, durability, elasticity or fine feature detail. Today's availability of multiple materials to match nearly any project is a testament to the expeditious evolution of material development.

Nearly 15 years ago, Stratasys started out using wax with its FDM technology because it was easiest to develop due to its low temperature resistance. It is also commonly used in investment casting so it seemed a perfect segue from traditional manufacturing processes to rapid prototyping. As rapid prototyping gained momentum in the industry, the need for more functional prototypes rose demanding more durable materials.

ABS was developed to provide a more structurally sound prototype that enhanced testing for fit, function, durability and temperature resistance. ABS is a highly functional material that engineers use for prototypes and for end-use parts. It is widely used in applications where impact-resistance and structural strength are necessary. In addition, its dimensional stability positions it as an ideal material for pre-production rapid prototypes that can accurately predict performance of injection molded parts.

Now, more than 10 years after the introduction of ABS, Stratasys introduced a material that is even stronger and more functional that ABS. According to the spec sheet, ABS M30 is 25-70 percent stronger than traditional ABS. That increase in strength provides more prototyping and digital manufacturing options for designers and engineers. RedEye is currently in the process of implementing additional system capacity that can use the new material to provide enhancements across a number of mechanical properties, including Tensile strength, Impact strength, and Flexural strength.

The constant evolution of better, stronger, more functional materials is setting the stage for rapid prototyping to completely evolve into digital manufacturing - providing a real alternative for the industry to choose FDM over injection molding.